High-feed turning of AISI D2 tool steel using multi-radii tool inserts: Tool life, material removed, and workpiece surface integrity evaluation

Khan, Sarmad Ali; Ahmad, Muhammad Aftab; Saleem, Muhammad Qaiser; Zakria, Ghulam; Qureshi, Muhammad Asif

doi:10.1080/10426914.2016.1232815

Cited by 36 publications

(15 citation statements)

References 17 publications

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“…To estimate the throughput advantages and assess the complete capabilities of A-type prime insert, experiments were piloted at higher values of C S , D OC , and F R . The ranges of C S and F R were cautiously selected from the literature on the turning of D2 steel [13,18,20] to target the performance with the current tooling, while the D OC values were chosen as per the manufacturer's recommendation [35,36]. The levels of the selected three input variables are provided in Table 3.…”

Section: Experimental Workmentioning

confidence: 99%

“…It has preferred the production facets of the machining overall. Seeing that the degree of interest might not be established for turning of difficult-to-cut materials [12], investigators have commenced precise examinations to explore the capabilities of the inserts for explicit circumstances [13][14][15]. The attentions to estimating the factual ability of inserts in machining of difficult-to-cut material are nonetheless continued.…”

Section: Introductionmentioning

confidence: 99%

“…They observed that the coated carbide inserts outstripped costly PCBN tooling because of the development of lubricious tribo-layer at the rake side of the insert. Khan et al [13] examined the high feed turning of AISI D2 tool steel with C-type-rhombic insert of different nose radii (0.4, 0.8, 1.2 mm). They observed that wear progressions were smooth for 0.4-and 0.8-mm nose radius inserts, while fracture occurred at the insert having a nose radius of 1.2 mm and at a high feed rate of 0.562 mm/rev.…”

Section: Introductionmentioning

confidence: 99%

“…Wiper inserts show the benefit of employing higher feed rates and improved surface roughness. However, low depth of cut (< 0.30 mm) and cutting speed limit their usage due to the reduced material removal rate [13,33].…”

Section: Introductionmentioning

confidence: 99%

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An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

Khan

Ameer

Uddin

et al. 2022

Int J Adv Manuf Technol

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Over the years, machinists have been exploring the hard part turning of AISI D2 steels. Initially, cylindrical grinding was used for this purpose, but it was later replaced by single-point turning due to its advantages such as high material removal, low cost, and greater flexibility. Conventional inserts are used in single-point turning, but they have been reported to have large radial forces, high notch wear, and poor surface finish. Therefore, multi-radii wiper inserts were designed to overcome these machining issues, but their use was restricted to shallower depths of cut and moderate feed rates because of the thick chips produced by the high entry angle. Prime inserts, on the other hand, were designed with a modest entry angle, making them ideal for evaluating tool wear/life, material removal and surface roughness at greater cutting speeds, depths of cut, and feed rates. It was observed that cutting speed has a significant effect on tool wear/life with a contribution of 55.38% followed by feed rate (13.72%) and depth of cut (11.43%). Cutting speed (84.87%) and feed rate (13.01%) are observed to be the most significant parameters controlling material removed. It was also observed that feed rate has a significant effect on workpiece surface roughness with a contribution of 67.30% followed by depth of cut (20.60%), whereas cutting speed had no significant effect on surface roughness. Moreover, it is found that prime insert outperformed wiper and conventional inserts in terms of tool life/wear and surface roughness.

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Section: Experimental Workmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

Khan

Ameer

Uddin

et al. 2022

Int J Adv Manuf Technol

Self Cite

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show abstract

“…Authors conducted an experimental study while machining D2 tool steel with wiper inserts and found that feed rate is the major factor that affects the surface roughness. Further in depth analysis of surface integrity microhardness was extended up to 150µm beneath the machined surface, and no white layer formation was found after machining [7]. Denni Kurniawan et al used wiper inserts for the metal removal process of martensitic stainless steel at different material removal speeds and feed rate, and found that combination of truncated feed rate and speed generated the higher tool life with better surface finish [8].…”

Section: Introductionmentioning

confidence: 99%

Influence of Wiper and Conventional Inserts at Profile Geometry During Turning of D2 Tool Steel

Nazir¹,

Ahmad²,

Bhutta³

et al. 2018

ETOAJ

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Latest inventions in the field of manufacturing drive the new technologies and different sources of production and to design the various sources to enhance the productivity as well as to reduce the cost, while maintaining the required specifications and high standards of the products. For achieving the production with high quality, tool manufacturers are continuously improving cutting edge, coating, geometry and the material of the tool. The tool geometry affects different aspects of tool like cutting temperature, tool wear and tool life, surface roughness, dimensional accuracy and surface integrity in the machining. The existing study is an attempt to explore the effect of wiper and conventional insets at profile turning. In this research inserts (wiper and conventional) having three different tool of nose radius (0.4, 0.8 and 1.2mm respectively) were evaluated at cutting speed (150m/min), feed rate levels (0.05. 0.10, 0.15, 0.20mm/rev), and depth of cut (0.2mm). Workpiece surface roughness (Ra) dimensional accuracy and microhardness of the machined surface were assessed. It was found that in profile turning in case of conventional inserts with larger nose radius of 1.2mm performed better than the other two inserts in term of surface roughness and dimensional accuracy. While in case of wiper inserts surface roughness and dimensional accuracy results were not better as comparing to conventional inserts. Microhardness under the machined surface was increased in both the cases of wiper and conventional.

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An investigation into surface integrity of AISI P20 machined under the influence of spindle forced vibrations

Zahoor

Mufti

Saleem

et al. 2018

Int J Adv Manuf Technol

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High-feed turning of AISI D2 tool steel using multi-radii tool inserts: Tool life, material removed, and workpiece surface integrity evaluation

Cited by 36 publications

References 17 publications

An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

An in-depth analysis of tool wear mechanisms and surface integrity during high-speed hard turning of AISI D2 steel via novel inserts

Influence of Wiper and Conventional Inserts at Profile Geometry During Turning of D2 Tool Steel

An investigation into surface integrity of AISI P20 machined under the influence of spindle forced vibrations

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