Journal Press India^®

Author Details ( * ) denotes Corresponding author

In the present study, an attempt has been made to investigate the effect of machining parameters (cutting speed, feed rate, depth of cut and tool nose radius) on material removal rate and surface roughness in finish hard turning of H13 tool steel using carbide tool. The machining experiments were conducted based on response surface methodology (RSM) using face centered central composite design. A comprehensive analysis of variance (ANOVA) was used to fully identify the most influential parameters, and the adequacy of both fitted second order regression models were checked. 3D response surfaces and 2D contour plots were analyzed to completely observe the impact of combinatory different important interactive factors on the machinability behaviour under different turning conditions. The MRR and SR increase by increasing the cutting speed, feed rate and depth of cut. The depth of cut and feed rate are the most influential factors for increasing the MRR and SR respectively. Mathematical models for MRR and SR were developed by using Design Expert-9 software. Finally, a multi-objective optimization technique based on the use of desirability function (DF) technique was then applied to find optimal combinations of input machining parameters capable of producing the highest possible amount of MRR and lowest amounts of SR within process domain. The obtained predicted optimal results were then verified experimentally to compute confirmation errors. The values of relative validation errors, all being found to be quite satisfactory, 5.29% for MRR and 8.1% for SR, proves the efficacy and reliability of suggested approach.

Keywords

Analysis of Variance (ANOVA), Desirability Function (DF); Face centered Central (FCC) Composite Design; Multi-Objective Optimization; Response Surface Methodology (RSM)

1. M. Thomas, Y. Beauchamp, Statistical investigation of modal parameters of cutting tools in dry turning, International Journal of Machine Tools & Manufacture 43, 2003, 1093–1106


2. S. S. Bosheh, P. T. Mativenga, White layer formation in hard turning of H13 tool steel at high cutting speeds using CBN tooling, International Journal of Machine Tools & Manufacture, 46, 2006, 225–233


3. M. Liu, Jun-ichiro Takagi, A. Tsukuda, Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel, Journal of Materials Processing Technology, 150, 2004, 234–241


4. W. Grzesik, Influence of tool wear on surface roughness in hard turning using differently shaped ceramic tools, Wear 265, 2008, 327–335


5. G. Poulachon, A. Moisan, I.S. Jawahir, Tool-wear mechanisms in hard turning with polycrystalline cubic boron nitride tools, Wear 250, 2001, 576–586


6. D. I. Lalwani, N. K. Mehta, P. K. Jain, 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, 2008, 167–179


7. Bouchelaghem, M. A. Yallese, T. Mabrouki, A. Amirat, J. F. Rigal, Experimental investigationa and performance analysis of CBN insert in hard turning of cold work tool steel (D3), Machining Science and Technology, 14, 2010, 471-501


8. J. A. Arsecularatne, L. C. Zhang, C. Montross, P. Mathew, On machining of hardened AISI D2 steel with PCBN tools, Journal of Materials Processing Technology, 171, 2006, 244–252


9. Li Qian, M. R. Hossan, Effect on cutting force in turning hardened tool steels with cubic boron nitride inserts, Journal of Materials Processing Technology, 191, 2007, 274–278


10. T. Ding, S. Zhang, Y. Wang, X. Zhu, Empirical models and optimal cutting parameters for cutting forces and surface roughness in hard milling of AISI H13 steel, International Journal of Advance Manufacturing and Technology, 2010, 51:45–55


11. Tug˘rul O¨ zel, Yig˘it Karpat, Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks, International Journal of Machine Tools & Manufacture, 45, 2005, 467–479


12. Reginaldo T. Coelho, Eu-Gene Ng, M. A. Elbestawi, Tool wear when turning hardened AISI 4340 with coated PCBN tools using finishing cutting conditions, International Journal of Machine Tools & Manufacture, 47, 2007, 263–272


13. D. Philip Selvaraj, P. Chandramohan, M. Mohanraj, Optimization of surface roughness, cutting force and tool wear of nitrogen alloyed duplex stainless steel in a dry turning process using Taguchi method, Measurement, 49, 2014, 205–215


14. S. Sarkar, M. Sekh, S. Mitra, B. Bhattacharyya, Modeling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation, journal of materials processing technology, 205, 2008, 376–387


15. K. Kumar, S. Agarwal, Multi-objective parametric optimization on machining with wire electric discharge machining, International Journal of Advance Manufacturing and Technology, 62, 2012, 617–633


16. K. Kumar, A. Dvivedi, S. Kumar, Parametric optimisation of surface roughness on wire-EDM using Taguchi method, Int. J. Manufacturing Technology and Management, 2011, 24, 1/2/3/4.


17. S. Assarzadeh, M. Ghoreishi, Statistical modeling and optimization of the EDM parameters on WC-6%Co composite through a hybrid response surface methodology-desirability function approach, International Journal of Engineering Science and Technology, 5, 2013, 1279-1302