Surface Roughness Prediction Model in Machining of Carbon Steel by PVD Coated Cutting Tools

Abstract

Abstract:The surface roughness model in the turning of AISI 1040 carbon steel was developed in terms of cutting speed, feed rate and depth of cut using response surface methodology. Machining tests were carried out using PVD-coated tools under different cutting conditions. The surface roughness equations of cutting tools when machining the carbon steels were achieved by using the experimental data. The results are presented in terms of mean values and confidence levels. The established equation shows that the feed rate was found to be a main influencing factor on the surface roughness. It increased with increasing the feed rate, but decreased with increasing the cutting speed and the depth of cut, respectively. The variance analysis for the second-order model shows that the interaction terms and the square terms were statically insignificant. However, it could be seen that the first-order effect of feed rate was significant while cutting speed and depth of cut was insignificant. The predicted surface roughness of the samples was found to lie close to that of the experimentally observed ones with 95% confident intervals.

An experimental analysis and measurement of process performances in machining of nimonic C-263 super alloy

“…The scale of the desirability function ranges between d = 0, which suggests that the response is completely unacceptable, and d = 1, which suggests that the response is exactly of the target value. The value of d increases as the desirability of the corresponding response increases [20].The optimization analysis was carried out using the DESIGN-EXPERT software.…”

Prediction of Surface Roughness in the Machining of Carbon Steels by Cutting Tools

“…Surface roughness value as function of trial number for TP100 and CM cutting tools. Response surface methodology was studied with a few other researchers [8][9]13,19,21]. It can bee seen from this figure that the Ra increased with increasing the feed rate for both tools significantly.…”

“…The past few decades have witnessed great advancements in the development of these cutting tools. However, a little work on the machining of this type of steel materials has given to the analysis and prediction of tool life [8][9][10][11][12] and surface roughness [13][14][15][16][17][18][19][20][21]. The use of coated tools to machine difficult-to-cut materials actually represents state of the art machining technology and today's machining processes are becoming increasingly demanding upon cutting tool materials.…”

Surface Roughness Parameters Model for Machining GFRP Composites by Cemented Carbide Tools

“…In order to know the surface quality and dimensional properties, it is necessary to employ theoretical models for prediction purpose. For prediction, the response surface method (RSM) is used and is practical, economical and relatively easy of use (Sahin and Motorcu, 2004). Table 2 was chosen, which had 9 rows corresponding to the number of tests.…”