Investigation of tool wear, surface roughness, sound intensity, and power consumption during hard turning of AISI 4140 steel using multilayer-coated carbide inserts

The present study investigated the machinability aspects, namely, surface roughness, sound intensity, power consumption, and crater wear, during dry turning of hardened AISI 4140 steel (63 HRC) employing (TiCN/Al2O3/TiN) multilayer-coated carbide inserts under dry cutting condition. The relationship between machining parameters and output parameters was determined using the Taguchi design. The analysis of variance was employed to evaluate the contributions of input parameters on output parameters. The main effect plots illustrated the impacts of cutting speed, feed, and depth of cut on response variables. Results show that the feed was the most dominant factor that affects surface roughness. Increasing the feed value increases the surface roughness, power consumption, and sound intensity. In the other part of this study, the constant values for feed (0.3 mm/rev), depth of cut (0.7 mm), and cutting speed (150 m/min) have been selected to evaluate a tool life that has 0.3 mm crater wear criteria. The results indicated that multilayer-coated carbide inserts presented very good tool life and reached 0.3 mm in 90 min. The experimental study results showed that chipping and abrasion were found to be the significant wear mechanism during hard turning of AISI 4140 steel. The cutting speed was the most significant parameter on the tool wear, although high cutting speed results the good surface finish but adversely increases the tool crater wear.

Analysis the effect of cutting speed on wear and crystal structure on CVD and PVD layer carbide insert materials

It has been done analysis effect of cutting speed on wear and crystal structure on CVD and PVD layer carbide inserts has been performed. The purpose of the study was to determine the effect of cutting speed on wear, crystal size, dislocation density and micro lattice strain on CVD and PVD layer carbide insert materials to cut the AMS5643 stainless steel material. CVD and PVD layer carbide insert cutting process with cutting speed variation 113; 126; 140; 175 m/min with cutting motion of 0.38 mm/round and depth of cut 1.5 mm fixed. Wear test results showed that CVD layer carbide insert wear was 15% higher than PVD layer carbide inserts. The results showed that the size of CVD layer carbide insert crystals was smaller than PVD layer carbide inserts by 42% and the dislocation density of CVD layer carbide inserts made no significant difference to PVD layer carbide inserts, as well as micro lattice strains for CVD layer carbide inserts greater than PVD layer carbide inserts.

Graph Theory and Matrix Approach for Machinability Enhancement of Cryogenic Treated Cobalt Bonded Tungsten Carbide Inserts

Cryogenic treatment is a sustainable manufacturing process preferred to improve the properties of the material. In the present study, the effect of cryo treated tungsten carbide cobalt bonded insert (WC-Co) measured in terms of tool life and surface finish on dry turning on high strength AISI4340 steel at different machine parametric conditions. The observations of Untreated (UT) and Deep Cryo Treated (DCT) inserts were compared. Formation and the distribution of eta phase carbides are verified by Scanning Electron Micrograph (SEM). The DCT insert shows a reduction in 27.27% tool wear with an acceptable level of surface finish. Taguchi's coupled Graph Theory and Matrix Approach (TC-GTMA) is used to predict the optimum machining condition and to substantiate the results the validation experiment is conducted and found satisfactory.

Tool Wear Characteristics of TiCn/Al2O3 Coated Carbide Inserts while Turning Glass Fiber Reinforced Epoxy Resin under Cryogenic Cooling

The main issue in machining glass fiber reinforced polymers is a rapid wearing of the cutting tool caused by the superior properties of the fiber reinforcement within the matrix. Cooling in machining processes reduces tool wear and extends tool life. Cryogenic cooling is an alternative method for effective, environmentally friendly, clean and safe cooling. This paper studied the tool wear characteristics of carbide inserts coated with TiCN and Al2O3 in turning glass fiber reinforced epoxy resin pipe. The cutting parameters were various, with cutting speed, feed rate, depth of cut and cutting conditions (without cooling and with cryogenic cooling). Not all cutting speeds that were cooled under cryogenics showed good outcomes. However, the experimental results suggest that using high cutting speed at 1800 rpm and high feed rate at 0.13 mm/rev, together with cryogenic cooling, can reduce the flank wear of the tool compared with no cooling.

Evaluation of the Performance of Cryogenically Treated Carbide İnserts in the Turning of AISI 1040 Steel

-In this study, the effects of cryogenic treatment on tool wear and surface roughness of tungsten carbide inserts coated with TiAlN were investigated as a function of cutting speed and feed rate. It is observed that the surface roughness increases with increased cutting speed, feed rate and also applied cryogenic processing. In other words, the effect of feed rate and cutting speed is very high on the surface roughness. On the other hand, the results showed that the cryogenic treatment is a non-effective process to enhance the wear resistance and tool life of inserts due to brittle region between coated layer and surface