Comparative Performance In Hard Turning Of AISI 1015 Steel With Carbide Insert Using Orthogonal Array Design And Grey Relational Analysis Under Spray Impingement Cooling And Dry Environment: A Case Study

1. Introduction

For manufacturing industries machining operations such as turning is the most suitable finishing process because it is made fast and efficient in which some processes like rough machining and fine grinding is eliminated and raw material is supplied in the final heat treated condition (Konig, Komanduri, Tonshoff, & Ackershon, 1984), i.e. it generally involves three sequential steps of manufacturing hardened components i.e. rough machining of unhardened steel, heat treated to the required hardness and finish machining to the required dimensional accuracy. Turning is a form of machining or a material removal process which is used to create rotational parts by cutting away unwanted material to give better surface quality on the workpiece. During this process large amount of heat is generated at the chip tool interface. This heat generated has large effect on life of the cutting tools used to cut the machined parts as well as it affects the surface quality of the workpiece, therefore in hard turning, selection of suitable cutting parameters, superior cutting tool like coated carbide or ceramic insert, workpiece material are important (Klocke, & Eisenblatter, 1997) to improve quality response and high material removed.

Although by introduction of cutting fluid at the cutting zone, better cutting performance can be achieved which will result in better surface finish, low cutting force and reduction of tool wear (Dhar, Kamuzzaman, & Ahmed, 2006) but according to the regulations of Occupational Safety and Health Administration (OSHA) using coolant liquid possess threat to the environment. Under dry environment metal cutting which is considered as safety to the environment (Sreejith, & Ngoi, 2000) leads to complex and mutual interactions between tool and workpiece at the contact surface. Therefore there are applications which require parts with hardness values within the range of 40–45 HRC are to be study under the proper selection of cutting parameter such as cutting speed, feed rate, depth of cut and even other factors like air pressure or water pressure, etc.