“…At that instant, microcrack is delocalize as well as distributed along the length of chip and looks like a saw tooth. Similar aspects regarding chip morphology have been reported by some researchers [4,[24][25][26].…”
Low cost machining puts tremendous pressure on the research in machining hardened steel compared to traditional grinding. As environmental regulations are strict enough on application of cutting fluids, a novel method called spray impingement cooling (SIC) assisted hard turning has been studied. The current work explores the distinguish wear modes, surface characteristics, chip-tool interface temperature and chip morphology in turning of AISI D2 steel by coated carbide tools (TiN/TiCN/Al 2 O 3 /TiN). The results revealed the favorable chip tool interaction during machining in context to surface roughness, surface topology, flank wear, chip morphology, chip reduction coefficient and tool life. In the SIC, evaporation occurred due to atomization of water jet and sufficient to generate significant cooling as maximum temperature has been found as 200.6 0 C. Modes of wear like abrasion, chipping and catastrophic breakage are noticed at tool-tip in hard turning. The optimal settings of parameters are founds as ap1-fn1-vc2 i.e. depth of cut-0.1 mm; feed-0.04 mm/rev; cutting speed-108 m/min. At these parametric conditions, the measured tool life is found as 20.3 minutes.
“…At that instant, microcrack is delocalize as well as distributed along the length of chip and looks like a saw tooth. Similar aspects regarding chip morphology have been reported by some researchers [4,[24][25][26].…”
Low cost machining puts tremendous pressure on the research in machining hardened steel compared to traditional grinding. As environmental regulations are strict enough on application of cutting fluids, a novel method called spray impingement cooling (SIC) assisted hard turning has been studied. The current work explores the distinguish wear modes, surface characteristics, chip-tool interface temperature and chip morphology in turning of AISI D2 steel by coated carbide tools (TiN/TiCN/Al 2 O 3 /TiN). The results revealed the favorable chip tool interaction during machining in context to surface roughness, surface topology, flank wear, chip morphology, chip reduction coefficient and tool life. In the SIC, evaporation occurred due to atomization of water jet and sufficient to generate significant cooling as maximum temperature has been found as 200.6 0 C. Modes of wear like abrasion, chipping and catastrophic breakage are noticed at tool-tip in hard turning. The optimal settings of parameters are founds as ap1-fn1-vc2 i.e. depth of cut-0.1 mm; feed-0.04 mm/rev; cutting speed-108 m/min. At these parametric conditions, the measured tool life is found as 20.3 minutes.
“…These results are in exceptional concurrence with the results reported in literature. 39 Figure 15.SEM images showing the upper and lower tooth gap of chips produced at (a) v = 170 m/min, d = 0.15 mm, f = 0.08 mm/rev, during Exp. no.…”
AISI D3 steel is a new kind of hardened tool steel with excellent wear resistance. This hard material receives wide promotion, investigation, and application in the die manufacturing industries. In the machining of AISI D3 steel, tool wear has a close relationship with the presence of different constituent elements in the workpiece material and cutting conditions. This study reports an improved experimental investigation approach to the analysis of effect of cutting speed, feed rate, and depth of cut on cutting forces, surface roughness, tool wear, and chip morphology in high-speed turning of AISI D3 steel using a hybrid TiN-coated Al2O3 + TiCN mixed ceramic insert. The range of each parameter is set at different levels for the analysis purpose. The experimental observations show that the cutting force is predominantly influenced by the feed rate accompanied by the depth of cut. The predominant factor influencing flank wear is the feed rate accompanied by the depth of cut and cutting speed. Feed rate is one of the dominating factors that influences the surface finish characteristics. The characterization of tool wear and chip morphology was performed by a scanning electron microscope supplied with energy-dispersive X-ray spectroscopy pattern. The results demonstrated that the predominant wear mechanism of the multilayered hybrid-coated tool was flank wear, crater wear, adhesion wear, and abrasive wear.
“…The flank wear evolution ranges from 0.06 to 0.098 mm respectively. However it increases at slightly higher rate at higher cutting speed and feed of 190 m/min and 0.16 mm/rev respectively and reaches 0.155 mm (at run 4) but still within the limiting range of tool wear of 0.3 mm [20,29,30,31].The cutting inserts are free from any types of failures such as chipping, fracturing, and adhesion and induced regular flank wear with stable machining. Similar observations are noticed at depth of cut of 0.2mm (Run 5, 6, 7, 8), 0.3mm (Run 9, 10, 11 and 12) and 0.4mm (Run 13, 14, 15 and 16) respectively.…”
Section: Analysis Of Flank Wearmentioning
confidence: 92%
“…The measured surface roughness varies from 0.2 microns to 1.33 microns respectively which is below the criterion limit of 1.6 microns. [20,29,30,31] This justifies its implementation in hard turning as surface roughness values are comparable to traditional grinding operation and may be replaced.…”
The existing endeavor investigates on machinability characteristics through performance measurement of flank wear, surface quality and chip morphology during finish turning of AISI 52100 bearing steel (55 ± 1 HRC) under dry environment employing carbide insert coated along with various layers (TiN/TiCN/Al2O3). Secondly the influence of machining variables viz. cutting speed, feed rate and depth of cut on responses are assessed by ANOVA and modeled through quadratic regression and artificial neural network. Multiparametric optimization of cutting conditions has been obtained through Taguchi based grey relational analysis. Finally, tool life at ideal conditions has been evaluated through experiment. Based on the study, it is disclosed that coated carbide with multilayer insert outperformed during hard machining as wear at the flank surface and surface quality are within the benchmark cap of 0.3 mm and 1.6 microns respectively. From the chip morphology analysis, multilayer coated carbide insert generates lower temperature and maintains cutting edge sharpness and delays the growth of tool wear. ANN model using multilayered feed forward network yields accurate prediction of responses with minimum error percentage compared to QR model. The optimal parametric combination through GRA approach is found to be d1 (0.1 mm)-f1 (0.04 mm/rev)-v2 (110 m/min) and is greatly improved. Feed is the compelling aspect for multi-responses pursued by cutting speed. The tool life at optimized cutting condition is found to be approximately 19 minutes.
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