Escolar Documentos
Profissional Documentos
Cultura Documentos
Measurement
journal homepage: www.elsevier.com/locate/measurement
a r t i c l e i n f o a b s t r a c t
Article history: The present work deals with some machinability studies on ank wear, surface roughness,
Received 1 March 2012 chip morphology and cutting forces in nish hard turning of AISI 4340 steel using uncoated
Received in revised form 17 April 2012 and multilayer TiN and ZrCN coated carbide inserts at higher cutting speed range. The pro-
Accepted 29 May 2012
cess has also been justied economically for its effective application in hard turning. Exper-
Available online 7 June 2012
imental results revealed that multilayer TiN/TiCN/Al2O3/TiN coated insert performed better
than uncoated and TiN/TiCN/Al2O3/ZrCN coated carbide insert being steady growth of ank
Keywords:
wear and surface roughness. The tool life for TiN and ZrCN coated carbide inserts was found
Finish hard turning
Coated carbide
to be approximately 19 min and 8 min at the extreme cutting conditions tested. Uncoated
Tool wear carbide insert used to cut hardened steel fractured prematurely. Abrasion, chipping and
Surface roughness catastrophic failure are the principal wear mechanisms observed during machining. The
Chip morphology turning forces (cutting force, thrust force and feed force) are observed to be lower using
Cutting force multilayer coated carbide insert in hard turning compared to uncoated carbide insert. From
Economic analysis 1st and 2nd order regression model, 2nd order model explains about 98.3% and 86.3% of
the variability of responses (ank wear and surface roughness) in predicting new observa-
tions compared to 1st order model and indicates the better tting of the model with the
data for multilayer TiN coated carbide insert. For ZrCN coated carbide insert, 2nd order
ank wear model ts well compared to surface roughness model as observed from ANOVA
study. The savings in machining costs using multilayer TiN coated insert is 93.4% compared
to uncoated carbide and 40% to ZrCN coated carbide inserts respectively in hard machining
taking ank wear criteria of 0.3 mm. This shows the economical feasibility of utilizing mul-
tilayer TiN coated carbide insert in nish hard turning.
2012 Elsevier Ltd. All rights reserved.
0263-2241/$ - see front matter 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2012.05.015
2154 A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165
Nomenclature
vapor deposition (PVD) techniques. Hard turning has been work tool steel with ceramic inserts. Lima et al. [8] inves-
applied now-a-days in many areas like production of bear- tigated the machinability of AISI D2 cold work tool steel
ings, gears, shafts and other mechanical components and (50 HRC) and AISI 4340 steel (42 HRC) using ceramic and
offers an attractive alternative to grinding. Hard turning coated carbide inserts. The results indicated that mixed
is generally performed by superior hard tools like CBN alumina inserts produced the surface nish comparable
and ceramic. The benets of hard turning are; reduction and close to cylindrical grinding. The principal wear mech-
of cost per product, good surface nish closer to grinding, anism is abrasion when turning the 42 HRC steel, whereas
high productivity, the ability to machine complex parts diffusion wear is predominant when machining the 50 HRC
by single setup thereby reducing setup times, less costly steel. Asiltrk and Akkus [9] carried out hard turning
equipment and environment friendly dry cutting. Due to experiment on hardened AISI 4140 steel (51 HRC) with
the development of PCBN cutting tools (commercially coated carbide insert using Taguchi orthogonal array for
available in the mid-1970s) and advanced ceramic grades, surface roughness. Results of this study indicate that the
the turning of steels with hardness values exceeding feed rate has the most signicant effect on Ra and Rz. In
50 HRC has been extensively investigated and successively addition, the effects of two factor interactions of the feed
replaces costly grinding operations reported by Lalwani rate-cutting speed and depth of cut-cutting speed appear
et al. [2]. to be important. However, other machinability characteris-
Park [3] observed that the radial force is the largest tics like tool wear and tool life, cutting force, chip morphol-
force component regardless the type of tool used, i.e. PCBN ogy and cutting temperature have not been considered for
or ceramic during turning hardened steel in dry conditions. study which is essential for hard turning. Sahoo and Sahoo
The specic cutting energy for the hard turning is found to [10] conducted hard turning of AISI 4340 steel (47 HRC)
be smaller than the specic grinding energy. Cutting force using multilayer ZrCN coated carbide insert and developed
and surface roughness is found to be smaller with the mathematical model for surface roughness and ank wear.
PCBN tools compared to ceramic tools under similar cut- The optimized process parameter for multiple perfor-
ting conditions. Ozel et al. [4] observed that surface rough- mance characteristics has been obtained using gray based
ness (Ra) values is as low as 0.180.20 lm with wiper Taguchi method and greatly improved. Mathematical mod-
ceramic inserts during hard turning of AISI D2 steel el output concluded that the RSM models proposed are sta-
(60 HRC). Tool ank wear reaches around 15 min consider- tistically signicant and adequate because of higher R2
ing ank wear criteria of 0.3 mm at high cutting speeds value. Rech [11] performed experiments on the character-
due to elevated temperatures. Sahin and Motorcu [5] ization of the frictional behavior of a reference coating
developed the surface roughness model using response such as TiN, and of new coatings such as (Ti, Al)N and
surface methodology in turning AISI 1050 hardened steels (Ti, Al)N + MoS2, deposited on a WCCo carbide substrate
by CBN cutting tools under different conditions. Feed rate during the machining of steels. It is observed that, the slid-
was found out to be the most signicant factor on the sur- ing ability of the TiN coating is a key parameter leading to a
face roughness. Singh and Venkateswara Rao [6] reported better wear resistance, compared to a (Ti, Al)N coating.
that the feed is the dominant factor determining the sur- Vikram Kumar and Ramamoorthy [12] compared the per-
face nish followed by nose radius and cutting velocity formance of different coated carbide tools in conventional
in nish hard turning of bearing steel (AISI 52100) using dry turning and wet turning processes with minimal uid
mixed ceramic inserts having different nose radius and dif- application method by varying speed and feed keeping
ferent effective rake angles. The effect of the effective rake depth of cut constant. More Abhijeet et al. [13] investi-
angle on the surface nish is less. But, the interaction ef- gated cBN plus TiN (cBNTiN) composite-coated carbide
fects of nose radius and effective rake angle are found to inserts for hard turning applications. The ank wear is pri-
be also signicant. Gaitonde et al. [7] revealed that, wiper marily due to abrasive actions of the martensite present
insert performed better with reference to surface rough- in the hardened AISI 4340 alloy. The crater wear of the
ness and tool wear, while the conventional insert is useful cBNTiN coated inserts is less than that of the PCBN inserts
in reducing the machining force, power and specic cut- because of the lubricity of TiN coating layer on the cBNTiN
ting force during turning of high chromium AISI D2 cold coating. The coated carbide inserts produce a good surface
A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165 2155
nish (<1.6 lm) and yield a tool life of about 18 min per uncoated carbide inserts and multilayer coated carbide in-
cutting edge. Noordin et al. [14] investigated on tool life serts (TiN/TiCN/Al2O3/TiN and TiN/TiCN/Al2O3/ZrCN) in dry
and surface nish during hard turning of AISI 420 stainless environment under higher parametric range. For econom-
steel (4748 HRC) using wiper carbide insert. Maximum ical feasibility of above carbide inserts in hard turning, a
tool life is found to be 18 min and the tool life decreased comparison between both inserts were made based on to-
at higher cutting speeds and feeds. Wear occurred at both tal machining cost per part. Therefore an attempt has been
the rake and ank faces with crater formation exposing made to know whether the newer generation coated car-
the carbide substrate indicating more severe wear on the bide tools can be effectively used for the hard turning
rake face. The wiper coated carbide tool resulted in very applications or not under dry environment at higher cut-
ne surface nish, much better than the theoretical values. ting speed.
Sharma et al. [15] studied machining variables such as cut-
ting forces and surface roughness which are measured dur- 2. Experimental conditions and procedures
ing turning at different cutting parameters such as
approaching angle, speed, feed and depth of cut. The data Experiments were carried out to study the growth of
obtained by experimentation is analyzed and used to con- ank wear, surface roughness and chip morphology (shape
struct model using neural networks. Vikram Kumar et al. and color) with respect to machining time for coated and
[16] compared the performance of TiCN and TiAlN coated uncoated inserts in hard turning of AISI 4340 steel
tools in machining AISI 4340 hardened steel under dry, (47 1 HRC) in dry environment under extreme parametric
wet and minimum uid application conditions. Minimum conditions. The chip morphology study has been done to
uid application yields better result compared to wet and identify the nature of chiptool interaction inuenced by
dry machining. However, the performance of the TiAlN using coated and uncoated carbide inserts. In this investi-
coated tool performed better with reference to wear resis- gation, higher parametric range (v = 150 m/min, f = 0.15
tance and surface nish on the components. Jiang et al. m/min and d = 0.4 mm) was taken to judge its performance
[17] presented the development of a nanocomposite cBN in hard turning and also assesses the tool life of both inserts.
TiN coating especially for hard turning. Aspects of the coat- The turning forces were measured and compared. The tool
ing on chip-breaker inserts, repeatability, and process opti- life criteria [20,21] were set based on a maximum ank
mization for the given application are discussed. wear width of VBc = 0.3 mm measured at tool nose radius
Encouraging tool life and work piece surface roughness corner and surface roughness criteria was taken as
have been achieved in machining of hardened steels (50 1.6 lm, i.e. comparable to cylindrical grinding. Cutting
53 HRC) using the coated inserts. de Lima et al. [18] per- was stopped when the tool ank wear width reached
formed turning operation of AISI 4340 steel hardened from 0.3 mm. The details of experimental conditions, instrumen-
250 to 525 HV using coated carbide tools to investigate its tations and measurements and the procedure used for the
potentials of applications in hard turning. It is observed study are discussed.
that, the machining force component increases with the
work material hardness. However, the cutting force de-
2.1. Test specimen
creases slightly as the work hardness increased from 250
to 345 HV. Tool wear was lower when machining the
The material used in the test for hard turning was AISI
345 HV workpiece compared with cutting the 250 HV steel
4340 steel of a 100 mm long and 45 mm diameter. The
and abrasion was the principal wear mechanism. Cata-
chemical composition of workpiece measured by Spectro
strophic failure takes place when attempting to machine
Metal Analyzer (Spectro Max) in weight% is as follows:
the 525 HV steel. Basak et al. [19] optimized process param-
0.397C, 0.389Si, 0.77Mn, 0.052P, 1.1Cr, 0.175Mo, 1.55Ni,
eters for surface roughness and tool wear in nish hard
0.64 W and 0.285Cu. The hardness of workpiece material
turning of D2 steel with ceramic tools using radial basis
after heat treatment was found to be 47 1 HRC.
function neural network model and found suitable in
selecting appropriate process parameters.
The current literature reports many investigations using
PCBN and ceramic tool on hardened steel, but the research
work carried out by multilayer coated carbide inserts on
hard turning are very limited. Thus, there is a need to inves-
tigate the machinability of hardened steel using low cost
coated carbide insert in details to explore its feasibility in
application in hard turning under dry environment. Usu-
ally, machinability of any combination of work-tool pair is
judged by (i) cutting temperature (ii) types and nature
of chips produced; (iii) cutting forces that affect power
consumption, dimensional accuracy and vibration, (iv) sur-
face nish, and (v) tool wear and tool life of insert. In the
present work, tool wear, tool life, surface roughness, chip
morphology and cutting forces are considered for study.
Thus, the current paper deals with some machinability
studies in nish hard turning of AISI 4340 steel using Fig. 1. Photograph of CNC Lathe.
2156 A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165
2.4. Cutting conditions The ank wear (VBc) were measured using Nikon
Prole Projector, model V10AD with a magnication of
The cutting condition for nish hard turning under 2050. The maximum ank wear land measured at
higher parametric condition is shown in Table 1. the tool corner (VBc) and taken as criteria of 0.3 mm. As
small depth of cut (0.4 mm) is chosen compared to tool
nose radius (0.8 mm), the tool wear occurs in the vicinity
of tool nose radius corner only. The visualization of images
Table 1
of ank surface of inserts was taken by stereo zoom micro-
Cutting conditions for hard turning.
scope (model RSM-8, Radical instrument, India) shown in
Cutting Descriptions Fig. 3. The experiment was stopped to measure the width
conditions
of ank wear land and surface roughness at each succes-
Workpiece AISI 4340 sive time.
Cutting time 0.46, 0.66, 0.9, 1.77, 3.44, 5.65, 8, 10.1, 15.63 and
19.48
Hardness 47 1 HRC 2.7. Study of chip pattern
Cutting speed 150 m/min
Feed 0.15 mm/rev The chip morphology (shape and color) is an important
Depth of cut 0.4 mm index of machinability study in metal machining. From the
Cutting environment
Dry
experiment, the chips were collected with successive
Cutting tools Uncoated carbide (TTS) [P2030] Tool 1 machining time and examined its shapes and colors by dig-
MTCVD TiN/TiCN/Al2O3/TiN coated carbide (TN ital camera to identify the nature of chiptool interaction
2000) [P1530] Tool 2 inuenced by using coated and uncoated carbide inserts
CVD TiN/TiCN/Al2O3/ZrCN coated carbide (TN
under dry environment.
7015) [P1020] Tool 3
Tool geometry CNMG120408
Tool holder PCLNR 2525 M12 2.8. Cutting force measurements
Overhang 30 mm
length
The experiment for turning forces were carried out on a
Responses Flank wear, surface roughness, chip morphology
capstan precision lathe (7KW spindle power, 1400 rpm
A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165 2157
Table 2
Flank wear and surface roughness data for hard machining of AISI 4340 steel.
Runs Machining time (Tc) in Flank wear land (VBc) in mm Surface roughness (Ra) in lm
min
Uncoated TiN coated ZrCN coated Uncoated TiN coated ZrCN coated
carbide carbide carbide carbide carbide carbide
1 0.46 0.263 0.025 0.015 0.765 0.987 1.065
2 0.66 0.44 - - 0.37 - -
3 0.9 0.6 0.029 0.016 0.42 1.19 1.195
4 1.77 0.71 0.039 0.028 0.505 0.95 0.605
5 3.44 - 0.12 0.15 - 0.987 0.755
6 5.65 - 0.169 0.28 - 0.86 0.945
7 8 - 0.211 0.324 - 1.007 1.147
8 10.1 - 0.221 - - 1.07 -
9 15.63 - 0.275 - - 1.205 -
10 19.48 - 0.315 - - 1.57 -
Fig. 5. Tool tips of uncoated carbide insert after machining times (a) 0.46 min, (b) 0.66 min, (c) 0.9 min and (d) 1.77 min.
oxidation resistance and thermal barrier property due steady wear and nally rapid stage of wear. Abrasion
to Al2O3 coating and adds wear resistance due to TiCN was found to be the major mechanism of ank wear in
coating. hard turning within studied range. When abrasive wear
4. The gradual growth of VBc for multilayer TiN coated dominates, scars on ank face are observed which is
insert indicates steady machining without any seen in TiN coated insert after 15.63 and 19.48 min of
premature tool failure by chipping or fracturing. The cut. At the rake surface, crater wear occurred due to high
machining time recorded to reach the wear limit for pressure and temperature at higher cutting speed
TiN coated carbide inserts was signicantly longer (150 m/min) and was closer to the cutting edge. The
(nearly about 19 min to reach 0.3 mm of ank wear edge under such condition is prone to catastrophic
limit) than that using ZrCN coated and uncoated carbide failure. This crater wear is observed due to sliding of
insert under extreme machining parameters. The three rough saw tooth chips on rake surface and brutal
zones of wear have been observed for TiN coated insert collapse of the auxiliary cutting edge is noticed at the
shown in Fig. 11, i.e. initial wear followed by gradual or 19.48 min of cut at higher cutting speed (150 m/min).
A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165 2159
Fig. 6. Tool tips of TiN coated carbide insert after machining times (a) 0.9 min, (b) 1.77 min, (c) 3.44 min, (d) 5.65 min, (e) 8 min, (f) 10.1 min, (g) 15.63 min
and (h) 19.48 min.
Till 10.1 min using TiN coated carbide inserts, helical to blue by the time ank wear reached the limiting value
chips with golden color have been obtained. However, (Fig. 9 and Table 3). This indicates a reduced rate of
during machining at 3.44 min, continuous spiral or rib- temperature rise during machining by TiN coated
bon type curling chip is observed (Fig. 9). This may be carbide insert. The surface roughness grows steadily
attributed that, during machining operation, a tempera- with time (Fig. 12) and within the recommended range
ture rise occurs near the tool tip due to rubbing action using multilayer TiN coated carbide insert than other
between the ank surface and workpiece particularly two inserts.
at break-in-wear period, where wearing phenomenon 5. For multilayer ZrCN coated carbide insert the tool life is
is comparatively faster. The ank wear at this stage is approximately 8 min at extreme cutting conditions as
increased from 0.039 mm to 0.12 mm. This causes the compared to uncoated carbide inserts (less than
localized thermal softening and increases the material 1 min). The extended tool life of ZrCN coated carbide
ductility that helps to produce continuous spiral curling tools may be due to its heat resistant layer and wear
chips. Due to low thermal conductivity property of TiN resistance due to TiCN coating. The surface roughness
coating, temperature in the lower side of chip increases of TiN and ZrCN coated carbide inserts were within
and causes a thermal bi-metallic effect between lower the recommended range of hard turning, i.e. within
and upper side of the chip that forces the chip to curl 1.6 lm. The magnitude of deterioration noted in ZrCN
also. Color of chip gradually changed from golden to coated tool is larger compared to TiN coated insert. Fail-
metallic by the end of 15.63 min. Color further changes ure of cutting ability of the ZrCN coated insert is
2160 A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165
Fig. 7. Tool tips of ZrCN coated carbide insert after machining times (a) 0.9 min, (b) 1.77 min, (c) 3.44 min, (d) 5.65 min and (e) 8 min.
Table 3
Shape and color of chips obtained at different machining time for uncoated and coated carbide inserts.
Machining time Uncoated carbide ZrCN coated carbide TiN coated carbide
(min)
Shape Color VBc Shape Color VBc Shape Color VBc
(mm) (min) (min)
0.46 Helical (Saw Burnt 0.263 - - 0.015 - - 0.025
tooth) blue
0.66 Ribbon (Saw Burnt 0.44 - - - - - -
tooth) blue
0.9 Ribbon (Saw Burnt 0.6 Helical Golden 0.016 Helical/ Golden 0.029
tooth) blue tubular
1.77 Ribbon (Saw Burnt 0.71 Helical/ Golden 0.028 Helical Golden 0.039
tooth) blue tubular
3.44 - - - Helical Blue 0.15 Ribbon Golden 0.12
5.65 - - - Helical Burnt 0.28 Helical Golden 0.169
blue
8 - - - Helical Burnt 0.324 Helical Golden 0.211
blue
10.1 - - - - - - Helical Golden 0.221
15.63 - - - - - - Helical Metallic 0.275
19.48 - - - - - - Helical Blue 0.315
Fig. 8. Chips produced by uncoated carbide tool at v = 150 m/min, f = 0.15 mm/ rev and d = 0.4 mm during machining times (a) 0.46, (b) 0.66, (c) 0.9, (d)
1.77 min.
A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165 2161
Fig. 9. Chips produced by TiN coated carbide tool at v = 150 m/min, f = 0.15 mm/ rev and d = 0.4 mm during machining times (a) 0.9, (b) 1.77, (c) 3.44, (d)
5.46,(e) 8,(f) 10.1, (g) 15.63, (h) 19.48 min.
Fig. 10. Chips produced by ZrCN coated carbide tool at v = 150 m/min, f = 0.15 mm/ rev and d = 0.4 mm during machining times (a) 0.9, (b) 1.77, (c) 3.44, (d)
5.65, (e) 8 min.
2.0
d = 0.4 mm Uncoated carbide
0.5
1.6
0.4
1.2
0.3
0.2 0.8
0.1
0.4
0.0
0 2 4 6 8 10 12 14 16 18 20 22 0.0
Machining Time, Tc (min) 0 2 4 6 8 10 12 14 16 18 20 22
Machining Time, Tc (min)
Fig. 11. Growth of ank wear with machining time.
Fig. 12. Growth of surface roughness with machining time.
1400 Uncoated carbide machining was stopped as it exceeded the ank wear
v = 150 m/min limit (Fig. 10 and Table 3). The burnt blue color chip
1200 f = 0.18 mm/rev indicates the excessive temperature involved in
d = 0.2 mm machining process and rapid deterioration of sharpness
Turning Forces (N)
4. Regression model
TiN coated carbide
320 v = 150 m/min From the previous investigation, it is revealed that the
f = 0.18 mm/rev multilayer TiN coated carbide insert performed better
280 d = 0.2 mm compared to multilayer ZrCN coated carbide and uncoated
Fy
Turning Forces (N)
Table 4
Analysis of variance for ank wear (VBc) 2nd order model (TiN coated).
Table 5 Table 7
Comparison of experimental and 2nd order model predicted ank wear Comparison of experimental and 2nd order model predicted surface
value (TiN coated). roughness value (TiN coated).
Observations Experimental Predicted 2nd order Residuals Observations Experimental Predicted 2nd order Residuals
value model value value model value
1 0.025 0.022 0.003 1 0.987 1.059 -0.072
2 0.029 0.035 -0.006 2 1.19 1.043 0.147
3 0.039 0.059 -0.02 3 0.95 1.015 -0.065
4 0.12 0.103 0.017 4 0.987 0.976 0.011
5 0.169 0.154 0.015 5 0.86 0.953 -0.093
6 0.211 0.201 0.01 6 1.007 0.964 0.043
7 0.221 0.235 -0.014 7 1.07 1.006 0.064
8 0.275 0.292 -0.017 8 1.205 1.257 -0.052
9 0.315 0.304 0.011 9 1.57 1.553 0.017
for both responses are very close to each other showing the
5. Economical feasibility
signicance of second order model developed (Tables 5
and 7). The maximum residuals are only 0.017 and 0.147
The basic endeavor of any production process is to pro-
for both the responses. So, second order model can be used
to predict the responses accurately in hard turning using duce an acceptable component at the minimum possible
cost. Tool life is considered as most important factor for
multilayer TiN coated carbide insert.
Similarly, using data from experiment, 2nd order model the study of economical aspect of metal cutting. The inves-
tigation reported whether a change from uncoated carbide
for multilayer ZrCN coated carbide insert have been devel-
oped and analyzed. The equations are furnished below. to coated carbide could be economically benecial for n-
2nd order model (ZrCN coated): ish hard turning operations or not. For economical justi-
cation in hard turning applying the uncoated and
VBc 0:037644 0:061877Tc 0:001897Tc2 ; R2 96:9%; multilayer TiN coated carbide inserts, a comparison be-
R2 adj 94:8% tween both inserts were made based on total machining
Ra 1:16756 0:21604 0:02748Tc2 ; cost per part according to Gilberts approach [13,25]. The
cost analysis was done for turning a cylindrical workpiece
R2 52:4%; R2 adj 20:7% with a nished diameter (D) of 40 mm and a length of cut
It is revealed that, 2nd order model explains about (L) of 100 mm. The cutting parameters (v = 150 m/min,
96.9% and 52.4% of the variability of responses in predict- f = 0.15 mm/rev and d = 0.4 mm) were the same as those
ing new observations using multilayer ZrCN coated carbide chosen for comparison of tool life taking ank wear criteria
insert. From Tables 8 and 9, it is evident that, the 2nd order VBc = 0.3 mm. The study is based on measuring tool life
model is statistically signicant for ank wear as their P- when using uncoated carbide, multilayer TiN coated and
value is less than 0.05 and F calculated value is more than ZrCN coated carbide in the nish hard turning of AISI
F-table value (9.55). Also, their predicted values are very 4340 steel and found to be approximately 0.55 min,
close to the experimental values being maximum residual 19 min and 8 min respectively.
restricted to only 0.038. However, the regression model From comparison cost Table 12, it is seen that, the total
(2nd order) for surface roughness is not that much signi- machining cost per part for TiN coated carbide insert (Rs
cant at 95% condence level from analysis of variance and 4.5) is comparatively less than uncoated (Rs 68.1) and
comparative study (Tables 10 and 11). ZrCN coated carbide tools (Rs 7.5). This indicates 15.1
Table 6
Analysis of variance for surface roughness (Ra) 2nd order model (TiN coated).
Table 8
Analysis of variance for ank wear (VBc) 2nd order model (ZrCN coated).
Table 12
Comparison of machining costs for inserts in nish hard machining.
Cutting conditions: v = 150 m/min, f = 0.15 mm/rev, d = 0.4 mm, L = 100 mm, VBc = 0.3 mm, Tc = 0.55 min and Td = 5 min, W/P = AISI 4340 (47 1 HRC).
A.K. Sahoo, B. Sahoo / Measurement 45 (2012) 21532165 2165
3. The three components of turning forces (Fx, Fy and Fz) [3] Y.W. Park, Tool material dependence of hard turning on the
surface quality, Int. J. Korean Soc. f Prec. Eng. 3 (1) (2002) 76
are noticed to be higher using uncoated carbide insert in
82.
nish hard turning compared to multilayer TiN and ZrCN [4] T. Ozel, Y. Karpat, L. Figueira, J.P. Davim, Modelling of surface nish
coated carbide inserts. Thrust force (Fy) is found to be and tool ank wear in turning of AISI D2 steel with ceramic wiper
the larger component of turning forces. Chipping and cata- inserts, J. Mater. Process. Technol. 189 (2007) 192198.
[5] Y. Sahin, A.R. Motorcu, Surface roughness model in machining
strophic failure of uncoated carbide insert is primarily due hardened steel with cubic boron nitride cutting tool, Int. J. Refract.
to such higher thrust force (950 N) and found unsuitable in Metals Hard Mater. 26 (2008) 8490.
hard turning within the parameter investigated. It is also [6] D. Singh, P. Venkateswara Rao, A surface roughness prediction model
for hard turning process, Int. J. Adv. Manuf. Technol. 32 (2007) 1115
evident that turning forces for ZrCN coated carbide insert 1124.
are slightly lower than TiN coated carbide insert during [7] V.N. Gaitonde, S.R. Karnik, L. Figueira, J.P. Davim, Machinability
machining. This reason may be attributed due to the higher investigations in hard turning of AISI D2 cold work tool steel with
conventional and wiper ceramic inserts, Int. J. Refract. Metals Hard
growth of wear during initial period of machining using Mater. 27 (2009) 754763.
TiN coated carbide insert. [8] J.G. Lima, R.F. vila, A.M. Abrao, M. Faustino, J.P. Davim, Hard
4. The surface roughness is within the recommended turning: AISI 4340 high strength alloy steel and AISI D2 cold work
tool steel, J. Mater. Process. Technol. 169 (3) (2005) 388395.
range of hard turning, i.e. within 1.6 lm for both multi- [9] I. Asiltrk, H. Akkus, Determining the effect of cutting parameters on
layer coated carbide inserts. From the study, it is evident surface roughness in hard turning using the Taguchi method,
that, the multilayer coated carbide inserts have performed Measurement 44 (2011) 16971704.
[10] A.K. Sahoo, B.D. Sahoo, Mathematical modeling and multi-response
well at a combination of cutting speeds (150 m/min), feed
optimization using response surface methodology and grey based
(0.15 m/min) and depth of cut (0.4 mm). However multi- Taguchi method: an experimental investigation, Int. J. Exp. Des.
layer TiN coated carbide insert performed well compared Process Optimis. 2 (3) (2011) 221242.
to ZrCN coated carbide insert due to steady wear growth [11] J. Rech, A multiview approach to the tribological characterisation of
cutting tool coatings for steels in high-speed dry turning, Int. J.
and higher tool life. Mach. Mach. Mater. 1 (1) (2006) 2744.
5. From 1st and 2nd order regression model, 2nd order [12] C.H.R. Vikram Kumar, B. Ramamoorthy, Performance of coated tools
model explains about 98.3% and 86.3% of the variability during hard turning under minimum uid application, J. Mater.
Process. Technol. 185 (2007) 210216.
of responses in predicting new observations compared to [13] S. More Abhijeet, W. Jiang, W.D. Brown, A.P. Malshe, Tool wear and
1st order model and indicates the better tting of the machining performance of cBN-TiN coated carbide inserts and PCBN
model with the data. Also, the predicted value and the compact inserts in turning AISI 4340 hardened steel, J. Mater.
Process. Technol. 180 (2006) 253262.
actual values for both ank wear and surface roughness [14] M.Y. Noordin, D. Kurniawan, S. Sharif, Hard turning of stainless steel
are very close to each other showing the signicance of using wiper coated carbide tool, Int. J. Prec. Technol. 1 (1) (2007) 75
second order model developed for multilayer TiN coated 84.
[15] V.S. Sharma, S. Dhiman, R. Sehgal, S.K. Sharma, Estimation of cutting
carbide insert in hard turning. forces and surface roughness for hard turning using neural
6. For multilayer ZrCN coated carbide insert, 2nd order networks, J. Intell. Manuf. 19 (2008) 473483.
ank wear model ts well and found to be statistically sig- [16] CH.R. Vikram Kumar, P. Kesavan Nair, B. Ramamoorthy, Performance
of TiCN and TiAlN tools in machining hardened steel under dry, wet
nicant compared to 2nd order surface roughness model.
and minimum uid application, Int. J. Mach. Mach. Mater. 3 (1/2)
7. The savings in machining costs using multilayer TiN (2008) 133142.
coated inserts is 93.4% compared to uncoated carbide and [17] W. Jiang, A.P. Malshe, R. Calvin Goforth, Cubic Boron Nitride (CBN)
40% to ZrCN coated carbide respectively in nish hard based nano composite coatings on cutting inserts with chip breakers
for hard turning applications, Surf. Coat. Technol. 200 (2005) 1849
machining taking ank wear limit of 0.3 mm. 1854.
8. A cost analysis, based on a single cutting edge, shows [18] J. G de Lima, R. F de vila, A.M. Abra, Turning of hardened AISI 4340
that the multilayer TiN coated carbide tools are capable steel using coated carbide inserts, Proc. IMechE, Part B: J. Eng. Manuf.
221 (2007) 13591366.
of reducing machining costs, and therefore, will be an [19] S. Basak, U.S. Dixit, J.P. Davim, Application of radial basis function
important complement to uncoated and ZrCN coated tools neural networks in optimization of hard turning of AISI D2 cold-
for nish hard turning applications. worked tool steel with a ceramic tool, Proc. IMechE, Part B: J. Eng.
Manuf. 221 (2007) 987998.
[20] M.A. Yallese, K. Chaoui, N. Zeghib, L. Boulanouar, J. Rigal, Hard
machining of hardened bearing steel using cubic boron nitride tool, J.
Acknowledgements Mater. Process. Technol. 209 (2009) 10921104.
[21] J.T. Horng, N.M. Liu, Ko-Ta Chiang, Investigating the machinability
evaluation of Hadeld steel in the hard turning with Al2O3/TiC
The authors would like to thank Central Tool Room and mixed ceramic tool based on the response surface methodology, J.
Training Centre (CTTC) and KIIT University, Bhubaneswar, Mater. Process. Technol. 208 (13) (2008) 532541.
[22] H. Gkkaya, M. Nalbant, The effects of cutting tool coating on the
Odisha and VSSUT, Burla, Odisha for their help and support
surface roughness of AISI 1015 Steel depending on cutting
towards experimental and measurement works. parameters, Turkish J. Eng. Env. Sci. 30 (2006) 307316.
[23] N.R. Dhar, S.V. Nanda Kishore, S. Paul, A.B. Chattopadhyay, The
References effects of cryogenic cooling on chips and cutting forces in turning
AISI 1040 and AISI 4320 steels, Proc. IMechE, Part B: J. Eng. Manuf.
216 (2002) 713724.
[1] W. Grzesik, The role of coatings in controlling the cutting process [24] Nilrudra Mandal, B. Doloi, B. Mondal, Reeta Das, Optimization of
when turning with coated indexable inserts, J. Mater. Process. ank wear using Zirconia Toughened Alumina (ZTA) cutting tool:
Technol. 179 (1998) 133143. Taguchi method and Regression analysis, Measurement 44 (2011)
[2] D.I. Lalwani, N.K. Mehta, P.K. Jain, Experimental investigations of 21492155.
cutting parameters inuence on cutting forces and surface [25] M.C. Shaw, Metal Cutting Principles, Oxford University press, New
roughness in nish hard turning of MDN250 steel, J. Mater. York, 2005.
Process. Technol. 206 (2008) 167179.