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

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

Purna Chandra Mishra (KIIT University, Odisha, India), Dipti Kanta Das (KIIT University, Odisha, India) and Susant Kumar Sahu (KIIT University, Odisha, India)
DOI: 10.4018/ijmmme.2014070101
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Abstract

This study investigates the effects of cutting parameters on surface roughness (Ra), cutting temperature (T0C) at the chip tool interface and the material removal rate (MRR mm3/min) during hard machining of AISI 1015 (43 HRC) steel using carbide insert under dry and spray impingement cooling environment. A combined technique using orthogonal array and analysis of variance (ANOVA) was employed to investigate the contribution of spindle speed, feed rate, depth of cut and air pressure on responses. Utilization of IR camera is been effective to calculate the temperature at the interface of workpiece and the tool. It is observed that with spray impingement cooling, cutting performance improves compared to dry cutting. The predicted multi response optimization setting (N3-f1-d1-P2) ensures minimization of surface roughness, cutting temperature and maximization of material removal rate. Finally optimal result was validated by confirmatory test and the improvement in grey relational grade was found to be 0.288.
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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.

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