The Effect of Cutting Parameters on Surface Integrity in Hard Turning

Article Preview

Abstract:

Manufacturers around the world constantly strive for lower cost solutions in order to maintain their competitiveness on machined components and manufactured goods. Globally, part quality has been found to be at acceptable levels and it continues to improve, while the pressure for part piece cost is enormous and is constantly being influenced downward by competition and buyer strategies. In machining processes, it is necessary to attain the desired surface quality in order to produce parts providing the required functioning. The surface quality is influenced by various cutting parameters (cutting speed, feed, depth of cut) and sometimes some other parameters. The objective of this paper is to review the effect of cutting parameters on surface integrity (surface roughness and residual stress) in hard turning.

You might also be interested in these eBooks

Info:

Periodical:

Pages:

751-757

Citation:

Online since:

October 2011

Export:

Price:

Permissions CCC:

Permissions PLS:

Сopyright:

© 2012 Trans Tech Publications Ltd. All Rights Reserved

Share:

Citation:

[1] O¨ zel, T., Hsu, T. and Zeren, E. Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel. Int. J. Adv. Manuf. Technol. 2005, Vol. 25 (3–4), p.262.

DOI: 10.1007/s00170-003-1878-5

Google Scholar

[2] Davim, J.P. and Figueira, L. Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques. Mater. Des. 2007, Vol. 28 (4), p.1186–1191.

DOI: 10.1016/j.matdes.2006.01.011

Google Scholar

[3] Mufioz-Escalona, P. and Cassier, Z. Influence of the critical cutting speed on the surface finish of turned steel. Wear 1998, Vol. 218 (1), p.103–109.

DOI: 10.1016/s0043-1648(98)00156-2

Google Scholar

[4] Benardos, P.G. and Vosniakos, G.C. Predicting surface roughness in machining: a review. Int. J. Mach. Tools Manuf. 2003, Vol. 43, p.833–844.

DOI: 10.1016/s0890-6955(03)00059-2

Google Scholar

[5] Feng, C.X.J. and Wang, X. Development of empirical models for surface roughness prediction in finish turning. Int. J. Adv. Manuf. Technol. 2002, 20, p.348–356.

Google Scholar

[6] Reddy, N.S. and Rao, P.V. Selection of optimum tool geometry and cutting conditions using a surface roughness prediction model for end milling. Int. J. Adv. Manuf. Technol. 2005, 26, p.1202–1210.

DOI: 10.1007/s00170-004-2110-y

Google Scholar

[7] Huddle, D. New hard turning tools and techniques offer a cost-effective alternative to grinding. Tooling and Production Magazine 2001, Vol. 80, pp.96-103.

Google Scholar

[8] Singh, D and Rao, P. V. A surface roughness prediction model for hard turning process. Int. J. Adv Manuf. Technology 2007, (32), p.1115–1124.

DOI: 10.1007/s00170-006-0429-2

Google Scholar

[9] Davim, P. J., Gaitonde,V. N. and Karnik, S. R. Investigations into the effect of cutting conditions on surface roughness in turning of free machining steel by ANN Models. Journal of Materials Processing Technology 2008, Vol. 205, p.16–23.

DOI: 10.1016/j.jmatprotec.2007.11.082

Google Scholar

[10] Jayant, A. and Kumar, V. Prediction of surface roughness in CNC turning operation using Taguchi design of experiments Vol. 88, March, (2008), pp.19-25.

Google Scholar

[11] Vishal S. Sharma, S. K. Sharma and Ajay K. Sharma . Cutting tool wear estimation for turning. J. Intell . Manuf. 2008. , Vol. 19, 1, pp.99-108.

DOI: 10.1007/s10845-007-0048-2

Google Scholar

[12] Cakir, M. C., Ensarioglu, C. and Demirayak, I. Mathematical modeling of surface roughness for evaluating the effects of cutting parameters and coating material. Journal of Materials Processing Technology. 2 0 0 9, Vol. 209, p.102–109.

DOI: 10.1016/j.jmatprotec.2008.01.050

Google Scholar

[13] Kahraman, F. The use of response surface methodology for prediction and analysis of surface roughness of AISI 4140 steel. Original Scientific Article MTAEC 9, 2009, Vol. 43(5), pp.267-270.

Google Scholar

[14] Prasad, M. V. R.D., Janardhana, G.R. and Rao, D. H. Experimental investigation to study the influence of process parameters in dry machining. Journal of Engineering and Applied Sciences Asian Research Publishing Network (ARPN), 2009, Vol 4(3), pp.91-94.

Google Scholar

[15] Suhail, . H., Ismail, N., Wong S. V. and Abdul Jalil, N. A. Optimization of cutting parameters based on surface roughness and assistance of workpiece surface temperature in turning process. American J. of Engineering and Applied Sciences 2010, 3 (1), pp.102-108.

DOI: 10.3844/ajeassp.2010.102.108

Google Scholar

[16] Saeed Zare Chavoshi and Mehdi Tajdari. Surface roughness modelling in hard turning operation of AISI 4140 using CBN cutting tool. Int. J. Mater Form 2010(3), p.233–239.

DOI: 10.1007/s12289-009-0679-2

Google Scholar

[17] M. Field, J.F. Kahles, Review of surface integrity of machined components, Annals of the CIRP 20 (2) (1971), p.153–163.

Google Scholar

[18] D.Y. Jang, J.H. Liou, T.R. Watkins, K.J. Kozaczek, C.R. Hubbard, Characterization of surface integrity in machined austenitic stainless steel, Manufacturing Science and Engineering, MED 3 (1) (1995), p.399–413.

Google Scholar

[19] Guo, Y. B., Li, W., Jawahir, I. S., Surface integrity characterization and prediction in machining of hardened and difficult-to-machine alloys, a state-of-the-art research review and analysis. Machining Science and Technology 2009, p.437–470.

DOI: 10.1080/10910340903454922

Google Scholar

[20] J. Hua, R. Shivpuri and D. Umbrello. Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel, J. Mater. Proc. Tech. 171 (2) (2006), p.180–187.

DOI: 10.1016/j.jmatprotec.2005.06.087

Google Scholar

[21] Batalha, G.F. , Delijaicov S., Aguiar, J.B. , Bordinassi ,E.C. and Stipkovic Filho ,M. , Residual stresses modeling in hard turning and its correlation with the cutting forces. Journal of Achievements in Materials and Manufacturing Engineering 2007, Vol 24(1), pp.350-356.

Google Scholar

[22] Ulutan,D., Erdem Alaca, B. and Lazoglu I. Analytical modelling of Residual stresses in machining. Journal of Materials Processing Technology 2007, Vol. 183, p.77–87.

DOI: 10.1016/j.jmatprotec.2006.09.032

Google Scholar

[23] Outeiro, J.C., Pina, J.C., M'Saoubi, R., Pusavec, F. and Jawahir, I.S. Analysis of residual stresses induced by dry turning of difficult-to-machine materials. CIRP Annals - Manufacturing Technology 2008, Vol. 57, p.77–80.

DOI: 10.1016/j.cirp.2008.03.076

Google Scholar

[24] Zhang Xuepinga , Gao Erwei and Richard Liub ,C. Optimization of process parameter of Residual stresses for hard turned surfaces . Journal of Materials Processing Technology 2009, Vol. 209, p.4286–4291.

DOI: 10.1016/j.jmatprotec.2008.10.011

Google Scholar

[25] Jaharah A.G., Wahid, S.W., Hassan, C.H., Nuawi M.Z. and Mohd Nizam, Rahman, A. The effect of uncoated carbide tool geometries in turning AISI 1045 using finite element analysis. European Journal of Scientific Research, 2009, Vol. 28, 2, pp.271-277.

Google Scholar

[26] Rizzuti, Umbrello,D., Filice ,L. and Settineri , L. Finite element analysis of residual stresses in machinings . Int. J. Mater Form 2010, Vol. 3, 1, p.431– 434.

DOI: 10.1007/s12289-010-0799-8

Google Scholar

[27] Caruso, S., Outeiro , J.C., Umbrello , D. and Saoubi ,R. Modeling and experimental validation of the surface residual stresses induced by hard machining of AISI H13 tool steel , Int. J. Mater. Form 2010, Vol. 3 (1), pp.515-518. B. Tech. in Mechanical Engineering from Banglore University-India (1994).

DOI: 10.1007/s12289-010-0820-2

Google Scholar