Response Surface Modeling and Optimization of Cutting Temperature in Turning of AISI 52100 Hardened Alloy Steel under Minimal Cutting Fluid Application

Abstract:

The heat generation and subsequent temperature rise in the cutting zone due to plastic deformation and friction at tool-chip-workpiece interface are critical parameters that have a significant impact on tool wear, tool life and surface integrity. This paper aimed to analyse the effect of cutting parameters such as, cutting speed, feed and depth of cut on the cutting temperature in turning of hardened AISI 52100 alloy steel of 58 HRC using multilayer coated carbide cutting tool insert under high velocity pulsing jet minimal cutting fluid application (MCFA) environment. Response surface methodology based central composite design (CCD) was used to investigate and optimize the cutting parameters on cutting temperature response. The quadratic regression model in terms of cutting speed, feed and depth of cut for cutting temperature was developed. The diagnostic and confirmatory tests were carried out to check its validity. The implication of the process parameters and their interactions were tested using analysis of variance (ANOVA). The results showed that the cutting speed and feed were the main significant parameters affecting the cutting temperature, while depth of cut and quadratic term of cutting speed had a moderate effect. The predictive model developed indicates the 99% desirability level in turning of AISI 52100 hardened steel under the MCFA environment. The predicted values of cutting temperature response are in close agreement with the experimental results.

• Periodical: Advances in Science and Technology (Volume 106)
• Pages: 60-67
• DOI: https://doi.org/10.4028/www.scientific.net/AST.106.60
• Online since: May 2021
• Authors: Sandip Mane*, Sanjay Kumar
• Keywords: Minimal Cutting Fluid Application, Response Surface Methodology, Surface Integrity, Tool Life, Tool Wear

References

[1] H.K. Tönshoff, C. Arendt, R. Ben Amor, Cutting of hardened steel, CIRP Annals-Manufacturing Technology, 49(2): (2000), 547–566.

DOI: 10.1016/s0007-8506(07)63455-6

[2] Suresh R., Basavarajappa S., V.N. Gaitonde, G.L. Samuel, Machinability investigations on hardened AISI 4340 steel using coated carbide insert. Int. Journal of Refractory Metals and Hard Materials 33: (2012),75–86.

DOI: 10.1016/j.ijrmhm.2012.02.019

[3] A.K. Sahoo and B. Sahoo, Experimental investigations on machinability aspects in finish hard turning of AISI 4340 steel using uncoated and multilayer coated carbide inserts. Measurement,45: (2012), 2153-2165.

DOI: 10.1016/j.measurement.2012.05.015

[4] NIOSH Metal Working Fluids - Recommendation for Chronic Inhalation Studies,, National Institute for Occupational Safety and Health (NIOSH), Cincinnati, OH USA, (2001), 45226.

[5] K. Leo Dev Wins and A.S. Varadarajan, An Environment Friendly Twin-jet Minimal Fluid Application Scheme for Surface Milling of Hardened AISI4340 Steel, International Journal of Manufacturing Systems, (2011), 30-45.

DOI: 10.3923/ijmsaj.2011.30.45

[6] P.K. Philip, A.S. Varadarajan and B. Ramamoorthy, Influence of cutting fluid composition and delivery variables on performance in hard turning using minimal fluid in pulsed jet form, Journal of the Institution of Engineers (India), (2000), 68-72.

[7] Vikram Kumar CH R. and B. Ramamoorthy, Performance of coated tools during hard turning under minimum fluid application, Journal of Materials Processing Technology, 185: (2007), 210–216.

DOI: 10.1016/j.jmatprotec.2006.03.148

[8] Vikram Kumar CH R., P. Kesavan Nair and B. Ramamoorthy, Performance of TiCN and TiAlN tools in machining hardened steel under dry, wet and minimum fluid application, International Journal of Machining and Machinability of Materials, 3 (1/2): (2008) 133-142.

DOI: 10.1504/ijmmm.2008.017630

[9] A.S. Varadarajan, P.K. Philip and B. Ramamoorthy, Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning, International Journal of Machine Tools and Manufacture, 42 (2002) 193–200.

DOI: 10.1016/s0890-6955(01)00119-5

[10] S.K. Shihab, A. Khan and A.N. Mohammad RSM Based Study of Cutting Temperature during Hard Turning with Multilayer Coated Carbide Insert,, Procedia Materials Science, 6:(2014) 1233-1242.

DOI: 10.1016/j.mspro.2014.07.197

[11] B. Fnides, M.A. Yallese and H. Aouici, Hard turning of hot work steel AISI H11: Evaluation of cutting pressures, resulting force and temperature. Mechanika 72: (2008) 59-63.

DOI: 10.3176/eng.2013.2.04

[12] H.M. Lin, Y.S. Liao and C.C. Wei, Wear behavior in turning high hardness alloy steel by CBN tool. Wear 264: (2008), 679–684.

DOI: 10.1016/j.wear.2007.06.006

[13] H. Bouchelaghem, M.A. Yallese, T. Mabrouki, A. Amirat and J.F. Rigal, Experimental Investigation and Performance Analyses of CBN Insert in Hard Turning of Cold Work Tool Steel (D3). International Journal of Machining Science and Technology 14: (2010),471–501.

DOI: 10.1080/10910344.2010.533621

[14] H. Aouici, M.A. Yallese, B. Fnides and T. Mabrouki, 'Machinability investigation in hard turning of AISI H11 hot work steel with CBN tool. Mechanika, 86: (2010), 71-77.

DOI: 10.1007/s12046-011-0007-7

[15] P. Ram Kumar K. Leo Dev Wins R. Robinson Ganadurai and A. S. Varadarajan, Investigations on hard turning with minimal multiple jet of cutting fluid,, Proceedings of the International Conference on Frontiers in Design and Manufacturing Engineering, (2008), 188-191.

[16] A.S. Varadarajan, P.K. Philip and B. Ramamoorthy Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning,, International Journal of Machine tools and Manufacture, 42:(2002), 132-200.

DOI: 10.1016/s0890-6955(01)00119-5

[17] Vikram Kumar CH, R. and B. Ramamoorthy, Performance of coated tools during hard turning under minimum fluid application,, Journal of Materials Processing Technology, 185: (2007), 210-216.

DOI: 10.1016/j.jmatprotec.2006.03.148

[18] K. Anil Raj, K. Leo Dev Wins and A.S. Varadarajan, Evaluation of the performance during hard turning of OHNS steel with minimal cutting fluid application and its comparison with minimum quantity lubrication,, IOP Conference Series: Materials Science and Engineering, 149: (2016).

DOI: 10.1088/1757-899x/149/1/012021

[19] R. Anil Raj, M. Dev Anand, K. Leo Dev Wins and A.S. Varadarajan (2010) ANFIS based Model for Surface Roughness Prediction for Hard Turning with Minimal with Cutting Fluid Application,, Indian Journal of Science and Technology, Vol 9(13) (2016), ISSN (Print): 0974-6846.

DOI: 10.17485/ijst/2016/v9i13/90562

[20] A.S. Varadarajan, P.K. Philip and B. Ramamoorthy, Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning,, International Journal of Machine Tools and Manufacture, 42 (2): (2002),193–200.

DOI: 10.1016/s0890-6955(01)00119-5

[21] A. Panda, A.K Sahoo., I. Panigrahi and A.K. Rout (2018), Investigating machinability in hard turning of AISI 52100 bearing steel through performance measurement: QR, ANN and GRA study,, International Journal of Automotive and Mechanical Engineering, 15 (1): 4935-4961.

DOI: 10.15282/ijame.15.1.2018.5.0384