Optimization of cutting parameters with respect to roughness for machining of hardened AISI 1040 steel

Abstract

Today, energy consumption and environmental issues are important topics in all industries around the globe. However, quality is in direct proportion with energy consumption, since better surface finish means more energy consumption. The main objective of this work is minimizing both surface roughness and power consumption by estimating the optimum machining parameters. In this study, turning tests were carried out on three different hardened AISI 1040 steels (10, 15, 20 HRC) at three different depths of cuts (1.2, 2.4, 3.6 mm), feed rates (0.15, 0.25, 0.35 mm × rev−1) and cutting speeds (120, 140, 160 m × min−1) without coolant. The effects of cutting parameters and workpieces hardness on surface roughness, sound level and power consumption were examined. These analyses were conducted using a full factorial experimental design method. The response surface methodology and analysis of variance were also used to determine the effects of input parameters on the response variables. Experimental results showed that an increase in the feed rate value causes an increase in the surface roughness, the sound level, and the power consumption values. The results of the presented work show that feed rate is the most effective machining parameter that affects surface roughness and power consumption. Following feed rate, depth of cut and cutting speed also have an important impact. Thus, decreasing the value of feed rate and depth of cut will reduce the amount of power consumption.

An investigation of cutting parameters effect on sound level, surface roughness, and power consumption during machining of hardened AISI 4140

“…The surface roughness has a decisive effect on obtaining a long-lasting and highquality machine for the user and manufacturing company. Thus, many studies have been carried out on this subject [2][3][4][5]. In this study, the research has been carried out to obtain high surface quality, especially in hard turning.…”

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

“…Material. In this research, a commercial and commonly used AISI 1040 steel [26,30,37], whose chemical composition and mechanical properties are shown in Table 1, was used.…”

“…e analysis gave short results for the proper selection of instruments in Inconel 718's turning process. In the study of Şahinoglu and Rafighi [26], turning tests were conducted on three different hardened AISI 1040 steels at three different cutting depths, feeding rates, and noncoolant cutting speeds. e study aimed mainly at minimizing both surface ruggedness and power consumption by estimating optimized machining parameters.…”

Comparison of Ceramic and Coated Carbide Inserts Performance in Finish Turning of Hardened AISI 420 Stainless Steel

“…Few studies were performed related to the machinability of the stainless steels [8][9][10][11]. Other studies focused on the machinability of the hardened steels in turning process [12][13][14]. Makadia and Nanavati [10] presented the effect of machining factors on the surface roughness in turning of hardened AISI 410 SS with ceramic inserts.…”