Surface Roughness Analysis in High Speed-Dry Turning of a Tool Steel

Abstract

High-speed machining is widely applied for the processing of lightweight materials and also structural and tool steels. These materials are intensively used in the aerospace and the automotive industries. The advantages of high-speed machining lie not only in the speed of machining (lower costs and higher productivity) but also in attaining higher surface quality (prescribed surface roughness without surface defects). Based on this concept, in the present paper the high speed-dry turning of AISI O, (manganese-chromium-tungsten / W.-Nr. 1.2510) tool-steel specimens is reported. The influence of the main machining parameters i.e., cutting speed, feed rate and depth of cut on the resulted center-line average surface roughness (Ra) is examined. Types of wear phenomena occurred during the course of the present experimental study as well as tool wear patterns were also monitored.

Multi-response optimization of CuZn39Pb3 brass alloy turning by implementing Grey Wolf algorithm

“…n the case of steels it was identified [9,22], that surface roughness decreases with increasing cutting speed and decreasing depth of cut and feed rate; such a behavior was not observed for the CuZn39Pb3 brass alloy. During the present series of experiments it is observed that high values for rotational speed in relation to moderate feeds are necessary to minimize surface roughness, whilst combinations of low speeds and low-to-moderate feeds favor the minimization of main cutting force; see Table 2.…”

“…Due to the various factors influencing surface integrity in turning, non-competitive production times as well as poor surface finish may be experienced which in turn degrade functional behavior of turned components [8]. Therefore, as it occurs in any other metal cutting process and any other engineering material, finding the optimal process parameters is of paramount importance [8,9]. Arc-chain surface patterns are quite often in turning, yet; significant deviations may be observed owing to irregular chip formation phenomena such as discontinuous chip, built-up edge, low feeds, chattering and intense tool flank wear.…”

Green Machining and Forming by the use of Surface coated tools

“…This can lead to improvement in surface finish. N.M. Vaxevanidis analyzed the surface roughness in high speed dry turning of tool steel and concluded that surface roughness becomes better as the cutting speed increases for same feed rate and depth of cut [9].The Fig2 shows the variation of surface roughness with feed. For feed rates between 0.03 and 0.06 mm /rev, the roughness values are more since the feed rates are low when compared with recommended feed.…”

Balancing multiple criteria in formulation of weighted, single-objective genetic algorithm optimization for CNC machining problems

“…As a statistical output, machining time can be easily estimated from CAM module, whereas surface roughness can only be measured by performing actual cutting experiments and using specialized instrumentation. Nevertheless if actual machining experiments are to be conducted to support such studies, exponential relations can be generated and served as prediction models [16]. The relation applied to compute R a is shown as…”