Experimental investigation on flank wear and tool life, cost analysis and mathematical model in turning hardened steel using coated carbide inserts

Sahoo, A.; Sahoo, B.

Growing Science » International Journal of Industrial Engineering Computations » Experimental investigation on flank wear and tool life, cost analysis and mathematical model in turning hardened steel using coated carbide inserts

Journals

IJIEC Volumes

Volume 1 (17)
- Issue 1 (9)
- Issue 2 (8)

Volume 2 (68)
- Issue 1 (12)
- Issue 2 (20)
- Issue 3 (20)
- Issue 4 (16)

Volume 3 (76)
- Issue 1 (9)
- Issue 2 (15)
- Issue 3 (20)
- Issue 4 (12)
- Issue 5 (20)

Volume 4 (50)
- Issue 1 (14)
- Issue 2 (10)
- Issue 3 (12)
- Issue 4 (14)

Volume 5 (47)
- Issue 1 (13)
- Issue 2 (12)
- Issue 3 (12)
- Issue 4 (10)

Volume 6 (39)
- Issue 1 (7)
- Issue 2 (12)
- Issue 3 (10)
- Issue 4 (10)

Volume 7 (47)
- Issue 1 (10)
- Issue 2 (14)
- Issue 3 (10)
- Issue 4 (13)

Volume 8 (30)
- Issue 1 (9)
- Issue 2 (7)
- Issue 3 (8)
- Issue 4 (6)

Volume 9 (32)
- Issue 1 (9)
- Issue 2 (6)
- Issue 3 (7)
- Issue 4 (10)

Volume 10 (34)
- Issue 1 (8)
- Issue 2 (10)
- Issue 3 (8)
- Issue 4 (8)

Volume 11 (36)
- Issue 1 (9)
- Issue 2 (8)
- Issue 3 (9)
- Issue 4 (10)

Volume 12 (29)
- Issue 1 (9)
- Issue 2 (6)
- Issue 3 (8)
- Issue 4 (6)

Volume 13 (41)
- Issue 1 (10)
- Issue 2 (8)
- Issue 3 (10)
- Issue 4 (13)

Volume 14 (50)
- Issue 1 (11)
- Issue 2 (15)
- Issue 3 (9)
- Issue 4 (15)

Volume 15 (55)
- Issue 1 (19)
- Issue 2 (15)
- Issue 3 (12)
- Issue 4 (9)

Keywords

Authors

Countries

International Journal of Industrial Engineering Computations

ISSN 1923-2934 (Online) - ISSN 1923-2926 (Print) Quarterly Publication Volume 4 Issue 4 pp. 571-578 , 2013

Experimental investigation on flank wear and tool life, cost analysis and mathematical model in turning hardened steel using coated carbide inserts Pages 571-578 Download PDF

Authors: Ashok Kumar Sahoo, Bidyadhar Sahoo

DOI: 10.5267/j.ijiec.2013.05.003

Keywords: ANOVA, Coated carbide, Flank wear, Hard turning, Regression, Tool life

Abstract: Turning hardened component with PCBN and ceramic inserts have been extensively used recently and replaces traditional grinding operation. The use of inexpensive multilayer coated carbide insert in hard turning is lacking and hence there is a need to investigate the potential and applicability of such tools in turning hardened steels. An attempt has been made in this paper to have a study on turning hardened AISI 4340 steel (47 ± 1 HRC) using coated carbide inserts (TiN/TiCN/Al2O3/ZrCN) under dry environment. The aim is to assess the tool life of inserts and evolution of flank wear with successive machining time. From experimental investigations, the gradual growth of flank wear for multilayer coated insert indicates steady machining without any premature tool failure by chipping or fracturing. Abrasion is found to be the dominant wear mechanisms in hard turning. Tool life of multilayer coated carbide inserts has been found to be 31 minute and machining cost per part is Rs.3.64 only under parametric conditions chosen i.e. v = 90 m/min, f = 0.05 mm/rev and d = 0.5 mm. The mathematical model shows high determination coefficient, R2 (99%) and fits the actual data well. The predicted flank wear has been found to lie very close to the experimental value at 95% confidence level. This shows the potential and effectiveness of multilayer coated carbide insert used in hard turning applications.

How to cite this paper

 Sahoo, A & Sahoo, B. (2013). Experimental investigation on flank wear and tool life, cost analysis and mathematical model in turning hardened steel using coated carbide inserts.International Journal of Industrial Engineering Computations , 4(4), 571-578.

Refrences

Aggarwala, A., Singh, H., Kumar, P., & Singh, M. (2008). Optimizing power consumption for CNC turned parts using response surface methodology and Taguchi’s technique-A comparative analysis. Journal of Materials Processing Technology, 200, 373-384.

Gokkaya, H., & NALBANT, M. (2006). The effects of cutting tool coating on the surface roughness of AISI 1015 steel depending on cutting parameters. Turkish Journal of Engineering Environmental Science, 30, 307-316.

Horng, J-T., Liu, N-M., & Chiang, K. (2008). Investigating the machinability evaluation of Hadfield steel in the hard turning with Al2O3/TiC mixed ceramic tool based on the response surface methodology. Journal of Materials Processing Technology, 208 (1-3), 532-541.

Kudapaa, S., Narasimhan, K., Boppana, P., & Russell, W.C. (1999). Characterization and properties of MTCVD TiCN and MTCVD ZrCN coatings. Surface and Coatings Technology, 120-121, 259-264.

Lalwani, D.I., Mehta, N.K., & Jain, P.K. (2008). Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel. Journal of Materials Processing Technology, 206 (1-3), 167-179.

More, A.S., Jiang, W., Brown, W.D., & Malshe, A.P. (2006). Tool wear and machining performance of cBN-TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel. Journal of Materials Processing Technology, 180, 253-262.

Montgomery, D.C. (1997). Design and Analysis of Experiments, 4th ed. Wiley, New York.

Ozel, T., & Karpat, Y. (2005). Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks. International Journal of Machine Tools & Manufacture, 45, 467- 479.

Sahin, Y. (2009). Comparison of tool life between ceramic and cubic boron nitride (CBN) cutting tools when machining hardened steels. Journal of Materials Processing Technology, 209, 3478-3489.

Sahin Y., & Motorcu A.R. (2008). Surface roughness model in machining hardened steel with cubic boron nitride cutting tool. International Journal of Refractory Metals & Hard Materials, 26, 84-90.

Sahoo, A.K., & Sahoo, B. (2011). Mathematical modelling and multi-response optimisation using response surface methodology and grey based Taguchi method: an experimental investigation. International Journal of Experimental Design and Process Optimisation, 2(3), 221-242.

Sahoo, A.K., & Sahoo, B. (2011). Surface roughness model and parametric optimization in finish turning using coated carbide insert: Response surface methodology and Taguchi approach. International Journal of Industrial Engineering Computations, 2, 819-830.

Singh, D., & Rao, P. V. (2007). A surface roughness prediction model for hard turning process. The International Journal of Advanced Manufacturing Technology, 32(11-12), 1115-1124.

Tamizharasan, T., Selvaraj, T., & Noorul Haq, A. (2006). Analysis of tool wear and surface finish in hard turning. International Journal of Advanced Manufacturing Technology, 28, 671-679.

T?nshoff, H., Wobker, H., & Brandt, D. (1995). Hard Turning - Influences on the Workpiece Properties. Transactions of NAMRI/SME, Vol. XXIII, 215-220.

T?nshoff, H., Arendt, C., & Ben Amor, R. (2000). Cutting of Hardened Steel. Annals of the CIRP, 49 (2), 547-565.

Yallese M.A., Rigal, J-F., Chaoui, K., & Boulanouar, L. (2005). The effects of cutting conditions on mixed ceramic and cubic boron nitride tool wear and on surface roughness during machining of X200Cr12 steel (60 HRC). Proc. IMechE, Part B: J. Engineering Manufacture, 219, 35-55.