Experimental investigations on wiper inserts’ edge preparation, workpiece hardness and operating parameters in hard turning of AISI D2 steel

Khan, Sarmad Ali; Umar, Muhamad; Saleem, Muhammad Qaiser; Mufti, Nadeem Ahmad; Raza, Syed Farhan

doi:10.1016/j.jmapro.2018.06.004

Cited by 35 publications

(22 citation statements)

References 35 publications

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“…Furthermore, wiper inserts when compared with conventional inserts were found to have the negative effect of increasing temperature on the tool rake face during machining, which will generate higher residual stresses and increase tool wear [42]. Nevertheless, in some previous studies, a better performance regarding tool wear was found when using wiper inserts than conventional [12,38]. Moreover, using wiper inserts showed high chip curling, which makes the chip separate earlier from the tool rake face [42].…”

Section: Introductionmentioning

confidence: 98%

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On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.

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Section: Introductionmentioning

confidence: 98%

“…Workpiece hardness has been found to have a considerable effect on output when machining using wiper inserts [38]. Others investigations of machining performance have included the effect of wiper insert on metal removal rate, cutting force, temperature and tool wear, and surface integrity [39,40].…”

Section: Introductionmentioning

confidence: 99%

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

et al. 2020

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“…It is suggested that the cutting speed has the most important effect on the cutting force, cutting temperature and tool life, while the feed rate has great influence on surface roughness. S. A. Khan [4] investigated the effect of wiper inserts' microgeometry for critical hardness regime of the material, employed two distinct edge geometries for wiper inserts in finish hard turning of AISI D2 steel without cutting fluid, machining workpieces of two different hardness (55HRC and 60HRC). Workpiece hardness was found to play the most significant role for tool life whereas for surface roughness, insert type and feed rate are found to be more dominant, maximum wear scar has been observed at the minor cutting edge with "Notching" being the prevalent wear mode.…”

Section: Introductionmentioning

confidence: 99%

Experimentation on Tool Wear and Surface Roughness in AISI D2 Steel Turning with WC Insert

López-Luiz¹,

Jiménez²,

Hernández³

et al. 2018

MME

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The Taguchi method, based on an orthogonal arrangement (L 9 , 3 3 ), the variance analysis, the signal-to-noise ratios and the response surface methodology have been used to optimize maximum flank wear (VB max ) and surface roughness (Ra) of the cutting tool when turning a hardened steel AISI D2 (65 HRC) with PVD-TiAlN coated WC insert upon dry environment. By employing regression models; cutting speed, cutting depth and feed rate, which optimize maximum flank wear and surface roughness were validated. Results of relation signal-to-noise ratios, showed that with cutting speed of 200 m/min, cutting depth of 0.2 mm and feed rate of 0.20 mm/rev, Ra is optimized. With cutting speed of 150 m/min, cutting depth of 0.4 mm and feed rate of 0.3 mm/rev, VB max is optimized. Through the variance analysis it was concluded that the depth of cut was the main parameter that affected on the surface roughness; whereas, the feed rate was the most influential parameter on the flank wear. Confirmation test results showed that the Taguchi method was very successful in the optimization of machining parameters for minimum surface roughness and flank wear in the turning of the D2 steel.

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“…In addition, when the literature is carefully examined, it is observed that the wiper insert had a positive effect on the surface roughness [8,9]. Wiper configuration has made it possible to employ higher feed rates in turning, at the same time keeping surface roughness as small as possible [10].…”

Section: E18mentioning

confidence: 99%

The Effect of Processing on The Surface and Subsurface Characteristic of Plastic Injection Mold Steel

Kamber¹,

Taşçıoğlu

2019

International Journal of Advances in Engineering and Pure Sciences

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AISI P20 is prehardened mold steel that is commonly used to manufacture plastic injection molding. The surface characteristics of molds play crucial role to control plastic injected molds parts. Besides, the characteristic of molds is mainly influenced by machining process, the manufacturing process to produce molds. This study presents the extensive experimental work focusing on the machining processing conditions on the surface characteristics of Plastic Injection mold steels. The input parameters are cutting speeds, feed rates and cutting inserts' geometry (wiper and non-wiper). The measured output parameters are subsurface hardness of machined parts and phase transformation induced from cutting process. Experimental results show that wiper insert significantly helps to improve surface quality of components. Besides, microhardness measurement shows that thermal softening occurs resulting from machining of this alloy. However, cutting speed has limited effect on the thermal softening response of this work material. XRD data illustrates peak broadening and increased intensity with machined samples.

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Experimental investigations on wiper inserts’ edge preparation, workpiece hardness and operating parameters in hard turning of AISI D2 steel

Cited by 35 publications

References 35 publications

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

Experimentation on Tool Wear and Surface Roughness in AISI D2 Steel Turning with WC Insert

The Effect of Processing on The Surface and Subsurface Characteristic of Plastic Injection Mold Steel

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