Experimental Investigation and Optimization of Machining AISI 1043 Steel Using Hard Turning Process

Abstract

In today’s rapidly developing new materials, metal machining industries face difficulties in getting the required surface finish. Optimization of machining parameters for hard turning process is crucial for finishing operations or the manufacturing unit to replace cylindrical grinding operation due to the development of advanced tool materials and rigid machine tools. The quality of surface finish gets influenced by different process parameters particularly in a finish hard turning operation. The aim of this research work is to investigate machining of hard materials and optimization of cutting parameters to achieve a better surface finish, reduce tool wear, and optimize material removal rate (MRR) in dry hard turning of hardened AISI 1043 steel. The cutting tool used for machining is a mixed Al2O3–TiC ceramic insert. Each experiment was repeated three times and each test used a new cutting insert to ensure accurate readings of the surface roughness. Besides, cutting temperature in the tooltip was predicted using an infrared thermometer and examined. As a methodology, the Taguchi L9 orthogonal array has been selected for the design of the experiments, and signal-to-noise ratio-based optimization has been utilized. Moreover, the analysis of variance (ANOVA) determined the influences of cutting parameters on the surface roughness. Also, different tooltip wear nature has been identified, and analysis showed that abrasion and chipping are two major wear mechanisms found for flank wear. Similarly, the lowest flank wear of 0.220 mm, and the moderate tooltip temperature of 67.50C is achieved for optimum cutting parameters. The result of variance presented that the influence of cutting speed, feed, and depth of cut were 74.22%, 22.33%, and 0.75% respectively. The lowest surface roughness attained for optimum cutting parameters is 1.24µm, and found that the hard turning can successfully substitute cylindrical grinding.

In Today?�?S Rapidly Developing New Materials, Metal Machining Industries Face Difficulties In Getting The Required Surface Finish. Optimization Of Machining Parameters For Hard Turning Process Is Crucial For Finishing Operations Or The Manufacturing Unit To Replace Cylindrical Grinding Operation Due To The Development Of Advanced Tool Materials And Rigid Machine Tools. The Quality Of Surface Finish Gets Influenced By Different Process Parameters Particularly In A Finish Hard Turning Operation. The Aim Of This Research Work Is To Investigate Machining Of Hard Materials And Optimization Of Cutting Parameters To Achieve A Better Surface Finish, Reduce Tool Wear, And Optimize Material Removal Rate (Mrr) In Dry Hard Turning Of Hardened Aisi 1043 Steel. The Cutting Tool Used For Machining Is A Mixed Al2o3?�?Tic Ceramic Insert. Each Experiment Was Repeated Three Times And Each Test Used A New Cutting Insert To Ensure Accurate Readings Of The Surface Roughness. Besides, Cutting Temperature In The Tooltip Was Predicted Using An Infrared Thermometer And Examined. As A Methodology, The Taguchi L9 Orthogonal Array Has Been Selected For The Design Of The Experiments, And Signal-To-Noise Ratio-Based Optimization Has Been Utilized. Moreover, The Analysis Of Variance (Anova) Determined The Influences Of Cutting Parameters On The Surface Roughness. Also, Different Tooltip Wear Nature Has Been Identified, And Analysis Showed That Abrasion And Chipping Are Two Major Wear Mechanisms Found For Flank Wear. Similarly, The Lowest Flank Wear Of 0.220 Mm, And The Moderate Tooltip Temperature Of 67.50c Is Achieved For Optimum Cutting Parameters. The Result Of Variance Presented That The Influence Of Cutting Speed, Feed, And Depth Of Cut Were 74.22%, 22.33%, And 0.75% Respectively. The Lowest Surface Roughness Attained For Optimum Cutting Parameters Is 1.24??M, And Found That The Hard Turning Can Successfully Substitute Cylindrical Grinding.