Performance studies of multilayer hard surface coatings (TiN/TiCN/Al2O3/TiN) of indexable carbide inserts in hard machining: Part-I (An experimental approach)

Sahoo, Ashok Kumar; Sahoo, Bidyadhar

doi:10.1016/j.measurement.2013.03.024

Cited by 48 publications

(28 citation statements)

References 27 publications

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“…The surface roughness was maximum in the uncoated cutting tool because of its rough surface morphology and porous microstructure. [37][38][39][40][41] The responsible factors for the input parameters based on the S=N ratios and the con¯rmation experimental results for the surface roughness are shown in Table 13.…”

Section: Cutting Force Analysismentioning

confidence: 99%

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

Kumar

Prabu

Kumar³

2017

J. Adv. Manuf. Syst.

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In the present work, the performances of TiAlN-, AlCrN-and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN-and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi's approach is used to obtain the best turning parameters, namely cutting speed (V ), feed rate (f) and depth of cut (d), in order to have a better surface¯nish and minimum tool°ank wear. An orthogonal array (L 9 Þ was used to conduct the experiments. The results show that the AlCrN/ TiAlN-coated cutting tool provided a much better surface¯nish and minimum tool°ank wear. The minimum tool°ank wear and minimum surface roughness were obtained using AlCrN/ TiAlN-coated tools, when V ¼ 160 m/min, f ¼ 0:318 mm/rev and d ¼ 0:3 mm.

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Section: Cutting Force Analysismentioning

confidence: 99%

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

Kumar

Prabu

Kumar³

2017

J. Adv. Manuf. Syst.

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“…Because surface roughness affects several functional attributes such as corrosion resistance, tribological characteristics, fatigue strength, and wear resistance of machined components, various researchers have employed methods which includes experimental, statistical, and analytical approaches in hard turning operation with various workpiece materials [18CrMo4, 42CrMo4, SEA8620, AISI 1040, 1045 for modeling and optimization using response surface methodology (RSM) (Elbah et al 2013;Hessainia et al 2013;Shihab et al 2014;Azam et al 2015;Meddour et al 2015;Bouzid et al 2015), Taguchi method (Gunay and Yucel 2013;Rashid et al 2016;Zerti et al 2016;Panda et al 2016;Das et al 2017a), ANN (Asiltürk and Çunkaş 2011;Pontes et al 2012;Asiltürk 2012;Mia and Dhar 2016), GRA (Sahoo and Sahoo 2013a;Kacal and Yildirim 2012;Senthilkumar et al 2014), GA (Batish et al 2014;Bouacha and Terrab 2016), and particle swarm optimization (PSO) (Stryczek and Pytlak 2014;Yue et al 2016) to attain the surface quality and dimensional finishing condition similar to costly cylindrical grinding. For example, Hessainia et al (2015) found that response surface methodology represents a powerful approach and can offer to scientific researchers as well industrial metal workers a helpful optimization procedure for various combinations of the workpiece and the cut material tool.…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Panda

Das

Dhupal

2017

Process Integr Optim Sustain

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The paper addresses the assessment, modeling, and optimization study of surface roughness in finish dry hard turning (FDHT) of AISI 4340 steel with coated ceramic tool by considering the cutting speed, axial feed, depth of cut, and nose radius as machining parameters. Thirty sets of longitudinal turning trials based on central composite (CCD) design of experiments (DOEs) are performed, and response surface methodology (RSM), particle swarm optimization (PSO), and finally, Gilbert's approach are subsequently applied for mathematical modeling, response optimization, tool life estimation, and economic analysis. Additionally, various diagnostic tests have been executed to check the statistical significance and validity, adequacy, effectiveness, and fitness of data of the proposed model using analysis of variance (ANOVA) and Anderson-Darling normal probability test. Results indicated that nose radius and feed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness is considered. The RSM model combined with PSO technique leads to minimum surface roughness value similar to cylindrical grinding of 0.2021 μm, corresponding to optimum process parameters: 220 m/min of cutting speed, 0.05 mm/rev of feed, 0.193 mm of depth of cut, and 1.6 mm of tool nose radius. Finally, under pre-cited optimum machining conditions, tool life was evaluated to perform cost analysis for the economical justification and feasibility of coated ceramic tools in hard turning. The total machining cost per piece is ensued to be lower ($0.34) as a consequence of higher tool life (44 min), reduction in downtime, and enhancement in savings, which finds economical benefits in hard turning. The novelty aspects of the present work are that (i) it demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing coated ceramic tool in hard turning processes considering technological, economical, and ecological aspects, which are helpful and efficient from industrial point of view and (ii) it contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-55 HRC.

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“…The flank wear evolution ranges from 0.06 to 0.098 mm respectively. However it increases at slightly higher rate at higher cutting speed and feed of 190 m/min and 0.16 mm/rev respectively and reaches 0.155 mm (at run 4) but still within the limiting range of tool wear of 0.3 mm [20,29,30,31].The cutting inserts are free from any types of failures such as chipping, fracturing, and adhesion and induced regular flank wear with stable machining. Similar observations are noticed at depth of cut of 0.2mm (Run 5, 6, 7, 8), 0.3mm (Run 9, 10, 11 and 12) and 0.4mm (Run 13, 14, 15 and 16) respectively.…”

Section: Analysis Of Flank Wearmentioning

confidence: 94%

“…The measured surface roughness varies from 0.2 microns to 1.33 microns respectively which is below the criterion limit of 1.6 microns. [20,29,30,31] This justifies its implementation in hard turning as surface roughness values are comparable to traditional grinding operation and may be replaced.…”

Section: Analysis Of Surface Roughnessmentioning

confidence: 99%

“…Raghavan et al [19] observed the possible advantages of laser tempering stationed turning operation over the traditional turning mechanism of heat treated AISI 52100 graded steel. Sahoo and Sahoo [20] investigated dry turning tests of AISI 4340 hardened steel having 47 HRC employing coated carbide tool concerning its machinability analysis. The investigation reveals the possibility of carbide insert coated with several layers in finish turning of hardened material even at higher cutting speeds.…”

Section: Introductionmentioning

confidence: 99%

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Investigating Machinability in Hard Turning of AISI 52100 Bearing Steel Through Performance Measurement: QR, ANN and GRA Study

Panda¹,

Sahoo²,

Panigrahi³

et al. 2018

INT. J. AUTOMOT. MECH. ENG.

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The existing endeavor investigates on machinability characteristics through performance measurement of flank wear, surface quality and chip morphology during finish turning of AISI 52100 bearing steel (55 ± 1 HRC) under dry environment employing carbide insert coated along with various layers (TiN/TiCN/Al2O3). Secondly the influence of machining variables viz. cutting speed, feed rate and depth of cut on responses are assessed by ANOVA and modeled through quadratic regression and artificial neural network. Multiparametric optimization of cutting conditions has been obtained through Taguchi based grey relational analysis. Finally, tool life at ideal conditions has been evaluated through experiment. Based on the study, it is disclosed that coated carbide with multilayer insert outperformed during hard machining as wear at the flank surface and surface quality are within the benchmark cap of 0.3 mm and 1.6 microns respectively. From the chip morphology analysis, multilayer coated carbide insert generates lower temperature and maintains cutting edge sharpness and delays the growth of tool wear. ANN model using multilayered feed forward network yields accurate prediction of responses with minimum error percentage compared to QR model. The optimal parametric combination through GRA approach is found to be d1 (0.1 mm)-f1 (0.04 mm/rev)-v2 (110 m/min) and is greatly improved. Feed is the compelling aspect for multi-responses pursued by cutting speed. The tool life at optimized cutting condition is found to be approximately 19 minutes.

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Performance studies of multilayer hard surface coatings (TiN/TiCN/Al2O3/TiN) of indexable carbide inserts in hard machining: Part-I (An experimental approach)

Cited by 48 publications

References 27 publications

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Investigating Machinability in Hard Turning of AISI 52100 Bearing Steel Through Performance Measurement: QR, ANN and GRA Study

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