Investigation on the Performance of Coated Carbide Tool during Dry Turning of AISI 4340 Alloy Steel

Abstract

The machinability of materials is highly affected by their hardness, and it affects power consumption, cutting tool life as well as surface quality while machining the component. This work deals with machining of annealed AISI 4340 alloy steel using a coated carbide tool under a dry environment. The microhardness of annealed and non-annealed workpieces was compared and a significant reduction was found in the microhardness of annealed samples. Microstructure examination of the annealed sample revealed the formation of coarse pearlite which indicated a reduction of hardness and improved ductility. A commercially CVD multilayer (TiN/TiCN/Al2O3/ZrCN) coated cemented carbide cutting tool was employed for turning quenched and tempered structural AISI 4340 alloy steel by varying machining speed, rate of feed, and depth of cut to evaluate the surface quality, machining forces, flank wear, and chip morphology. According to the findings of experiments, the feed rate possesses a high impact on surface finish, followed by cutting speed. The prominent shape of the serrated saw tooth chip was noticed at a higher cutting speed. Machined surface finish and cutting forces during turning is a function of the wear profile of the coated carbide insert. This study proves that annealing is a low-cost and economical process to enhance the machinability of alloy steel.

Influence of Tempering Temperature on Mechanical and Rotational Bending Fatigue Properties of 40CrNi2MoE Steel

“…40CrNi2MoE steel, belonging to the nickel–chromium–molybdenum series of low-alloy ultra-high-strength steels, epitomizes exemplary material characteristics, including notable strength, toughness, and favorable hardenability. As a result, its usage spans a wide range of applications, prominently in the manufacture of vital components like aircraft landing gears [ 1 , 2 ].…”

Study of the Effects of Five Different Machining Fluids on the Surface Hardness and Corrosion Behaviour of Al6061 Alloy

“…Numerous factors related to machining fluids, including pressure, application technique, cutting fluid flow rate, impact tool [16-,17]. Wagri et al, [19], the surface integrity of hardened AISI 4140 steel was studied while being turned using a scalable pulsed power plasma SPPP-AlTiSiN coated carbide tool with minimal quantity lubrication (MQL) assistance from nanofluids. Radiator coolant and zinc oxide nanoparticles are combined to create nano-cutting fluid.…”

“…As a result, it projected the entire machining cost per component to be Rs.23.12 in Indian rupees. In the study carried out by Wagri et al [19], it was confirmed that the hardness of a material significantly impacts its machinability, which in turn impacts the component's surface quality, power consumption, and cutting tool life [20]. However, the current machining fluid employed in the industry, e.g., soluble oil, is not environmentally friendly.…”

Exploring the Impact of the Turning of AISI 4340 Steel on Tool Wear, Surface Roughness, Sound Intensity, and Power Consumption under Dry, MQL, and Nano-MQL Conditions

“…Cooling of the machining zone is of paramount importance to address the problems caused by excessive heat. Many studies have been conducted to optimize cutting parameters of AISI 4340 alloy steel and improve the quality of the machined surface [3][4][5][6]. In these studies, researchers have focused on reducing surface roughness to ensure the integrity of the machined surface, minimizing tool wear and the resulting increase in cutting forces, reducing power consumption, enhancing machining efficiency, optimizing cutting parameters such as cutting speed and feed rate, as well as controlling pa-rameters such as cooling and lubrication methods, and exploring environmentally friendly green manufacturing [7].…”