Experimental Study & Optimization of Machining Parameters in Turning of AISI 1040 Steel with Micro-grooved WC Cutting Tools

Abstract

Abstract. In dry turning, control over chip formation and the need for the automated machining lead to an advancement in cutting tools. Such concern towards chip breakability is necessary in reducing tool wear, tool tip temperatures and surface roughness of workpiece material. The present study proposes a new development in the traditionally available cutting tools, which acts like a chip breaker. A series of micro-grooves are machined on the rake face of Tungsten carbide (WC) cutting tools using sinker Electric Discharge Machine (EDM). These micro-grooved tools are used to dissolve long continuous chips and heat from the cutting zone in the dry machining of AISI 1040 steel. The results of micro-grooved cutting tools have shown improvement in reducing the tool tip temperatures and surface roughness compared to the conventional cutting tools. The consolidated chip flow phenomenon of plain WC tools is used to decide the location of micro-grooves on the tool rake face. A Taguchi orthogonal array is used to design an experimental layout with minimum number of repetitions in the experiments. Signal-tonoise ratios and ANOVA is used to understand and identify the significant factors & their level among the input variables on responses.From the results, it is identified that the cutting speed is the most influencing parameter for tool tip temperature at level 1 (i.e.112 m/min) and surface roughness at level 5(i.e.720 m/min).

Studying and Optimizing the Effect of Process Parameters on Machining Vibration in Turning Process of AISI 1040 Steel

“…e study of Haque et al [27] found that feed rate, depth of cut, and cutting condition with water are the most significant factors affecting the surface roughness for turning of AISI 1040 steel. Prakash and Krishnaiah [28], Pavani et al [29], and Nair et al [30] studied the effect of cutting speed, feed rate, and depth of cut on surface roughness for turning of AISI 1040 steel. However, Nair et al [30] suggested the same three factors to study the effect of tool vibration on flank wear and surface roughness during high-speed machining of 1040 steel.…”