Machinability investigations on hardened AISI 4340 steel using coated carbide insert

International Journal of Refractory Metals and Hard Materials (Impact Factor: 1.99). 07/2012; 33. DOI: 10.1016/j.ijrmhm.2012.02.019


Hard turning AISI 4340 high strength low alloy steel Coated carbide inserts Machinability Design of experiments Response surface methodology The hard turning process with advanced cutting tool materials has several advantages over grinding such as short cycle time, process flexibility, compatible surface roughness, higher material removal rate and less en-vironment problems without the use of cutting fluid. However, the main concerns of hard turning are the cost of expensive tool materials and the effect of the process on machinability characteristics. The poor selection of the process parameters may cause excessive tool wear and increased work surface roughness. Hence, there is a need to study the machinability aspects in high-hardened components. In this work, an attempt has been made to analyze the influence of cutting speed, feed rate, depth of cut and machining time on machinability characteristics such as machining force, surface roughness and tool wear using response surface methodology (RSM) based second order mathematical models during turning of AISI 4340 high strength low alloy steel using coated carbide inserts. The experiments were planned as per full factorial design (FFD). From the para-metric analysis, it is revealed that, the combination of low feed rate, low depth of cut and low machining time with high cutting speed is beneficial for minimizing the machining force and surface roughness. On the other hand, the interaction plots suggest that employing lower cutting speed with lower feed rate can reduce tool wear. Chip morphology study indicates the formation of various types of chips operating under several cut-ting conditions.

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    • "Results revealed that cutting speed and interaction of feed with tool corner radius are affecting the flank wear significantly, while cutting speed and nose radius have significant effect on surface roughness. Suresh et al. [14] used a similar approach by considering the influence of cutting parameters (v,f,d) and machining time on machinability aspects like surface roughness, tool wear and machining force in turning AISI 4340 steel hardened at 48 HRC with coated carbide inserts. Davim and Figueira [15] applied statistical techniques to evaluate the machinability such as surface roughness, specific cutting pressure and flank wear in turning AISID2 steel hardened at 60 HRC with ceramic tool. "

    • "It was concluded that the feed rate and the cutting speed had significant effect, and the depth of cut and vibrations had no statistically significant effects on the surface roughness. AISI 4340 steel (hardness: 48 HRC) was examined by Suresh et al. [7]. The tool used throughout the investigation was CNMG 120408 with chip breaker. "
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    • "The other parameters which affect the surface roughness were tool radius and tool chamfer angle besides the feed rate [8] [16] [17] [18]. Older studies about investigate the effect of cutting parameters on cutting force and surface roughness, the depth of cut was founded the most influential parameter affecting the three cutting forces followed by the feed and for the greater results the minimum depth of cut values have to be chosen [7] [9] [10] [11] [14] [19]. According to the studies which was about on tool wear, coated tools has the better performance and has the longest cutting life that examined on hardened materials [20] [21]. "
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