SpringerLink
Log in

Surface roughness and cutting forces modeling for optimization of machining condition in finish hard turning of AISI 52100 steel

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

An experimental investigation was conducted to analyze the effect of cutting parameters (cutting speed, feed rate and depth of cut) and workpiece hardness on surface roughness and cutting force components. The finish hard turning of AISI 52100 steel with coated Al2O3 + TiC mixed ceramic cutting tools was studied. The planning of experiment were based on Taguchi’s L27 orthogonal array. The response table and analysis of variance (ANOVA) have allowed to check the validity of linear regression model and to determine the significant parameters affecting the surface roughness and cutting forces. The statistical analysis reveals that the feed rate, workpiece hardness and cutting speed have significant effects in reducing the surface roughness; whereas the depth of cut, workpiece hardness and feed rate are observed to have a statistically significant impact on the cutting force components than the cutting speed. Consequently, empirical models were developed to correlate the cutting parameters and workpiece hardness with surface roughness and cutting forces. The optimum machining conditions to produce the lowest surface roughness with minimal cutting force components under these experimental conditions were searched using desirability function approach for multiple response factors optimization. Finally, confirmation experiments were performed to verify the pertinence of the developed empirical models.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. T. Hodgson, P. Trendler and G. Ravignani, Turning hardened tool steels with cubic boron nitride inserts, Ann. CIRP. 30 (1981) 63–66.

    Article  Google Scholar 

  2. N. Narutaki, Y. Yamane and K. Okushima, Tool wear and cutting temperature of CBN tool in machining of hardened steels, Ann. CIRP. 28 (1979) 23–28.

    Google Scholar 

  3. X. L. Liu, D. H. Wen, Z. J. Li, L. **ao and F. G. Yan, Experimental study on hard turning hardened GCr15 steel with PCBN tool, J. Mater. Process. Technol. 129 (2002) 217–221.

    Article  Google Scholar 

  4. R. Pavel, I. Marinescu and M. Deis, J. Pillar, Effect of tool wear on surface finish for a case of continuous and interrupted hard turning, J. Mater. Process. Technol. 170 (2005) 341–349.

    Article  Google Scholar 

  5. T. Özel, T. K. Hsu and E. Zeren,, 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. 25 (2005) 262–269.

    Article  Google Scholar 

  6. S. Y. Luo, Y. S. Liao and Y. Y. Tsai, Wear characteristics turning high hardness alloy steel by ceramic and CBN tools, J. Mater. Process. Technol. 88 (1999) 114–121.

    Article  Google Scholar 

  7. M. Remadna and J. F. Rigal, Evolution during time of tool wear and cutting forces in the case of hard turning with CBN inserts, J. Mater. Proc. Technol. 178 (2006) 67–75.

    Article  Google Scholar 

  8. T. Sornakumar, M. V. Gopalakrishnan, R. Krishnamurthy and C. V. Gokularatnam, Development of alumina and Ce-TTZ ceramic composite (ZTA) cutting tool, Int. J. Refract. Metals. Hard. Mater. 13 (1995) 375–378.

    Article  Google Scholar 

  9. D. I. Lalwani, N. K. Mehta and P. K. Jain, Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel, J. Mater. Process. Technol. 206 (2008) 167–179.

    Article  Google Scholar 

  10. K. Nakayama, M. Arai and T. Kanda, Machining characteristics of hard materials, Ann. CIRP. 37 (1988) 89–92.

    Article  Google Scholar 

  11. M. A. Yallese, K. Chaoui, N. Zeghib, L. Boulanouar and J. F. Rigal, Hard machining of hardened bearing steel using cubic boron nitride tool, J. Mater. Process. Technol. 209 (2009) 1092–1104.

    Article  Google Scholar 

  12. H. K. Tönshoff, C. Arendt and R. Ben Amor, Cutting of hardened steel, Ann. CIRP. 49 (2000) 547–566.

    Article  Google Scholar 

  13. H. Aouici, M. A. Yallese, B. Fnides, K. Chaoui and T. Mabrouki, Modeling and optimization of hard turning of X38CrMoV5-1 steel with CBN tool: Machining parameters effects on flank wear and surface roughness, Journal of Mechanical Science and Technology 25(11) (2011) 2843–2851.

    Article  Google Scholar 

  14. W. König, R. Komanduri, H. Tönshoff and G. Ackershott, Machining of hard materials, Ann. CIRP. 33 (1984) 417–428

    Google Scholar 

  15. V. N. Gaitonde, S. R. Karnik, L. Figueira and J. P. Davim, Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts, Int. J. Refract. Metals. Hard. Mater. 27 (2009) 754–763.

    Article  Google Scholar 

  16. A. K. Basim and M. Bashir, Study of cutting speed on surface roughness and chip formation when machining nickelbased alloy, Journal of Mechanical Science and Technology 24(5) (2010) 1083–1090.

    Article  Google Scholar 

  17. Y. K. Chou and H. Song, Tool nose radius effects on finish hard turning, J. Mater. Process. Technol. 148 (2004) 259–268.

    Article  Google Scholar 

  18. C. M. Lee, Surface roughness and cutting force prediction in MQL and wet turning process of AISI 1045 using design of experiments, Journal of Mechanical Science and Technology 24(8) (2010) 1669–1677.

    Article  Google Scholar 

  19. J. H. Jung and W. T. Kwon, Optimization of EDM process for multiple performance characteristics using Taguchi method and Grey relational analysis, Journal of Mechanical Science and Technology 24(5) (2010) 1083–1090.

    Article  Google Scholar 

  20. M. S. Phadke, Quality engineering using robust design, Englewood Cliffs, New Jersey (1989).

    Google Scholar 

  21. P. J. Ross, Taguchi techniques for quality engineering, New York (1988).

  22. J. D. Thiele, S. N. Melkote, Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel, J. Mater. Process. Technol. 94 (1999) 216–226.

    Article  Google Scholar 

  23. H. A. Kishawy, M. A. Elbestawi, Effects of process parameters on material side flow during hard turning, Int. J. Mach. Tools. Manuf. 39 (1999) 1017–1030.

    Article  Google Scholar 

  24. D. C. Montgomery, Design and analysis of experiments, 5 ed., John Wiley & Sons Inc, New York (2001).

    Google Scholar 

  25. R. H. Myers and D. C. Montgomery, Response Surface Methodology: Process and Product Optimization Using Designed Experiments, 2nd ed., John Wiley and Sons, Inc.: New York (2002).

    MATH  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Mechanic and Structures Research Laboratory (LMS), University of Guelma, P.O. Box 401, 24000, Guelma, Algeria

    Mohamed Walid Azizi, Salim Belhadi & Mohamed Athmane Yallese

  2. CNRS, INSA-Lyon LaMCoS, UMR5259, University of Lyon, F69621, Lyon, France

    Tarek Mabrouki & Jean-François Rigal

Authors
  1. Mohamed Walid Azizi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Salim Belhadi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mohamed Athmane Yallese
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Tarek Mabrouki
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jean-François Rigal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mohamed Walid Azizi.

Additional information

Recommended by Editor Sung-Lim Ko

Mohamed Walid Azizi, Research Laboratory of Mechanics and Structures (LMS), University of Guelma. He received a Magister in rheological and Microstructures Science in 2009 at the department of metallurgy in Badji Mokhtar University Annaba, Algeria. His area of interest is design and analysis of experiments and hard machining process optimization.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Azizi, M.W., Belhadi, S., Yallese, M.A. et al. Surface roughness and cutting forces modeling for optimization of machining condition in finish hard turning of AISI 52100 steel. J Mech Sci Technol 26, 4105–4114 (2012). https://doi.org/10.1007/s12206-012-0885-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-012-0885-6

Keywords

Search

Navigation