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International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
DOI : 10.14810/ijmech.2015.4109 105
COMPARISON OF SURFACE ROUGHNESS
OF COLDWORK AND HOT WORK TOOL
STEELS IN HARD TURNING
Varaprasad.Bh1*
, Srinivasa Rao.Ch2
1*
Mechanical Engineering Department, GVP College for Degree and P.G. Courses,
School of Engineering (Technical Campus), Rushikonda, Visakhapatnam, India
2
Mechanical Engineering Department, Andhra University, College of Engineering (A)
Visakhapatnam, India.
ABSTRACT
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
Key words:
Hard turning, Surface Roughness, AISI D3, AISI H13, RSM and ANOVA.
1. INTRODUCTION
Hard turning is the process of single point cutting of hardened ferrous material with a hardness
value more than 45HRC in order to obtain finished workpieces directly from hardened parts [1-
5]. Hardened steels are most widely used in multiple industrial applications like automotive,
aeronautics, tool design and mold design.Many industrial steel components under influence of
critical loads from automotive and aerospace parts to bearing and forming tool are made of
hardened steel. These parts are normally finished by grinding, which is time consuming and
costly. For this reason, hard turning has become the most important substitute to grinding for
hardened steels [6, 7].With advent of new kind of tools such as Cubic Boron Nitride (CBN),
Polycrystalline Cubic Boron Nitride (PCBN), poly-crystalline diamond (PCD), coated, Chemical
Vapor Deposition (CVD), Physical Vapor Deposition (PVD) and ceramic tools, better surface
finish will be accessible without any finishing and complementary operation such as grinding.
Reduction in machining costs, elimination of cutting fluids, increase in the flexibility and
efficiency, reduction in part-handling costs and finally decrease in the set-up times when
compared to grinding process are the advantages of hard turning [1,4]. Achieving better surface
quality, tool life and dimensional accuracy are of crucial concerns in turning of hardened steels
[4]. The major focus of present research is on surface roughness of the machined surfaces and it is
one of the most important product quality characteristics. Achieving the suitable surface quality
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
106
in hard turning especially in comparison with grinding is of great importance to the functional
behavior of a machined part. Very few studies are reported on hard turning of AISI D3 with
ceramic tool and also comparison of machining of both AISI D3 and AISI H13. The main scope
of the present research is the experimental investigation of the effect of machining parameters
(i.e., cutting speed, feed rate, depth of cut) on surface roughness in hard turning process of AISI
D3 and AISI H13. In this experimental work, ANOVA is used to know the percentage of
contribution of each parameter on performance. To analyze the effect of process parameters on
surface roughness by plotting main effects graph and their individual interactions. Moreover,
RSM and regression analysis are used to establish the correlation between factors and responses.
Al2O3/TiN-coated tungsten carbide tools for finish-turning of NiCr20TiAl nickel-based alloy
under various cutting conditions, cutting forces, surface integrity and tool wear are investigated
and the inter-diffusing and transferring of elements between Al2O3/TiN-coated tungsten carbide
tool and NiCr20TiAl nickel-based alloy are studied [8]. Investigated the cutting performance of
tungsten carbide tools with restricted contact length and multilayer chemical vapor deposition
coatings, TiCN/Al2O3/TiN and TiCN/Al2O3–TiN in dry turning of AISI 4140 and the results show
that coating layouts and cutting tool edge geometry can significantly affect heat distribution into
the cutting tool [9]. Presented an optimization method of the machining parameters in high-speed
machining of stainless steel using coated carbide tool to achieve minimum cutting forces and
better surface roughness using Taguchi’s technique and pareto ANOVA and found that the feed
rate is found to be more significant followed by the cutting speed and the depth of cut [10].
A method developed to identify surface roughness based on measurement of workpiece surface
temperature and root mean square for feed vibration of the cutting tool during turning mild steel
using grey relational analysis [11]. Machinability of hardened steel using grey relational approach
and ANOVA to obtain optimum process parameters considering MRR, surface finish, tool wear
and tool life for both rough and finish machining [12]. Multi-response optimization of turning
parameters and nose radius over surface roughness and power consumed using Taguchi based
grey relational approach and found that the main influencing parameter is cutting speed followed
by feed rate and depth of cut [13]. In turning operations, for multi-response optimization Taguchi
based grey relational approach is used to identify the optimum conditions to obtain better results
[14, 15]. Prediction of flank wear and surface roughness during hard turning is performed using
uncoated carbide inserts of various tool geometries [16].
2. Experimentation
The materials used for experiments are AISI D3 and AISI H13. Bars of diameter 70 mm x 360
mm long are prepared. Test sample is trued, centred and cleaned by removing a 2 mm layer prior
to actual machining tests. The chemical composition of the work piece materials are given in
Table.1 and Table.2.The AISI D3 is oil-quenched from 980o
C (1800o
F) for hardening, followed
by tempering at 200o
C to attain 62HRC. The AISI H13 is hardened by oil quenching from 1050o
C
and tempered at 600o
C to attain 62 HRC.
Table.1 Chemical composition of AISI D3 (wt%)
C Si Mn P S Cr Ni Mo Al Cu Zn Fe
2.06 0.55 0.449 0.036 0.056 11.09 0.277 0.207 0.0034 0.13 0.27 84.8716
Table.2 Chemical composition of AISI H13 (wt%)
C Si Mn P S Cr Ni Mo V Fe
0.4 1.05 0.35 0.03 0.003 5.03 0.3 1.4 1.0 90.437
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
107
The lathe used for machining operations is Kirloskar; model Turn Master-35, spindle power
6.6KW.Surface roughness is measured using MitutoyoSurftest SJ 210 having measuring range of
17.5mm and skid force less than 400 mN. Four readings with a sample length of 0.8 mm are
recorded after each experiment and an average value is taken as the surface roughness. These
values are obtained without disturbing the assembly of the workpiece in order to reduce
uncertainties.
The cutting insert used is a mixed ceramic removable, of square form with eight cutting edges
and having designation SNGA 120408 T01020 (Sandvik make CC6050) is a mixed ceramic
grade based on alumina with an addition of titanium carbide. The high hot-hardness, the good
level of toughness makes the grade suitable as first choice for machining hardened steels (50 –
65HRC) in applications with good stability or with light interrupted cuts. The inserts are mounted
on a commercial tool holder of designation PSBNR 2525 M 12 (ISO) with the geometry of active
part characterized by the following angles: χ = 75°; α = 6°; γ = −6°; λ = −6°. Three levels are
defined for each cutting variable as given in Table.3. The variable levels are chosen within the
intervals according to recommendations made by the cutting tool manufacturer. Three selected
cutting variables at three levels led to a total of 20 tests.
Table.3. Assignment of the levels to the variables
Parameters Range
-1 0 +1
Speed(m/min) 145 155 165
Feed(mm/rev) 0.05 0.075 0.1
Depth of cut(mm) 0.3 0.6 0.9
3. ANALYSIS OF RESULTS
The analysis is made by considering experimental results of surface roughness (Ra) for various
combinations of cutting conditions (cutting speed, feed rate and depth of cut) as per the design
matrix. Data is analyzed statistically usingANOVA, Contour plots and Surface plots are shown
and discussed in the following sections.
3.1 Statistical Analysis
In RSM, the quantitative form of the relationship between the desired response and independent
input process parameters can be represented by [17].
ܻ = ∅൫ܸ௖, ݂, ܽ௣൯ (1)
Where Y is the desired response and f is the response function. In the present investigation, the
RSM-based mathematical model for surface roughness Ra, has been developed with cutting speed
Vc, feed rate f and depth of cut ap as the process parameters. The response surface equation for
three factors is given by [17].
ܻ = ܽ଴ + ܽଵܸ௖ + ܽଶ݂ + ܽଷܽ௣ + ܽଵଶܸ௖݂ + ܽଵଷܸ௖ܽ௣ + ܽଶଷ݂ܽ௣ + ܽଵଵܸ௖
ଶ
+ ܽଶଶ݂ଶ
+
ܽଷଷܽ௣
ଶ
(2)
Where Y; desired response and a1,............, a33; regression coefficients to be determined for each
response. The estimated Regression Coefficients for surface roughness of AISI D3 and AISI H13
for surface roughness Ra are shown in Table.4 and 5.
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
108
Table.4. Estimated Regression Coefficients for surface roughness of AISI D3Ra (microns)
ܴ௔ = −16.55 + 0.27 × ܺଵ − 121.55 × ܺଶ + 5.27 × ܺଷ + 1185.16 × ܺଶ
ଶ
																											 (3)
Where ܺଵ, ܺଶ and ܺଷSpeed, Feed and Depth of cut.
Table.5. Estimated Regression Coefficients for surface roughness of AISI H13 Ra(microns)
ܴ௔ = 73.66 − 0.94 × ܺଵ + 55.02 × ܺଶ − 7.49 × ܺଷ + 0.003 × ܺଵ
ଶ
+ 0.0611 × ሺܺଵ × ܺଶሻ (4)
Whereܺଵ is Speed, ܺଶ is Feed and ܺଷ is Depth of cut.
Scatter plots identifies the relationship between two variables whether the relationship is positive,
negative, or no relationship can be easily detected. It can be observed from figure.1 the residuals
are located on straight line, which means that the errors are distributed normally. Hence the
developed empirical models can represent the process significantly. Therefore these models can
be further used for optimization of process parameters such as speed, feed and depth of cut.
Term Coef SE Coef T P Remarks
Constant -16.55 29.814 -0.555 0.591 Insignificant
Speed(m/min) 0.27 0.39 0.69 0.506 Insignificant
Feed(mm/rev) -121.55 54.994 -2.21 0.049 Significant
DOC(mm) 5.27 4.22 1.248 0.241 Insignificant
Speed(m/min) x Speed(m/min) 0 0.001 -0.548 0.595 Insignificant
Feed(mm/rev) x Feed(mm/rev) 1185.16 200.614 5.908 0.000 Significant
DOC(mm) x DOC(mm) -0.35 1.393 -0.249 0.808 Insignificant
Speed(m/min) x Feed(mm/rev) -0.48 0.294 -1.639 0.132 Insignificant
Speed(m/min) x DOC(mm) -0.03 0.025 -1.102 0.296 Insignificant
Feed(mm/rev) x DOC(mm) -5.62 9.802 -0.573 0.579 Insignificant
S = 0.207925 PRESS = 2.99659
R-Sq = 92.80% R-Sq(pred) = 50.11% R-Sq(adj) = 86.32%
Term Coef SE Coef T P Remarks
Constant 73.6655 29.541 2.494 0.032 Significant
Speed(m/min) -0.9472 0.386 -2.453 0.034 Significant
Feed(mm/rev) 55.0202 54.49 1.01 0.336 Insignificant
DOC(mm) -7.497 4.181 -1.793 0.103 Insignificant
Speed(m/min) x Speed(m/min) 0.003 0.001 2.446 0.034 Significant
Feed(mm/rev) x Feed(mm/rev) 37.0473 198.776 0.186 0.856 Insignificant
DOC(mm) x DOC(mm) -0.2316 1.38 -0.168 0.87 Insignificant
Speed(m/min) x Feed(mm/rev) -0.3428 0.291 -1.176 0.267 Insignificant
Speed(m/min) x DOC(mm) 0.0611 0.024 2.515 0.031 Significant
Feed(mm/rev) x DOC(mm) -13.3917 9.712 -1.379 0.198 Insignificant
S = 0.206020 PRESS = 6.78960
R-Sq = 75.87% R-Sq(pred) = 0.00% R-Sq(adj) = 54.16%
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
109
3.2 Analysis of Variance
It is clear from the results of ANOVA that the feed is the dominant factor affecting surface finish
Ra. The second factor influencing Ra is cutting speed x feed for AISI D3 shown in table.6.
Table.7.shown below is ANOVA for AISI H13.To understand the hard turning process in terms
of surface roughness Ra, mathematical modelsare developed using multiple regression method.
Ra models are given by equations (3&4). Its coefficient of correlation R2
is 92.8 for AISI D3 and
its value 75.87 for AISI H13.
The ANOVA has been applied to check the adequacy of the developed models. The ANOVA
table consists of sum of squares and degrees of freedom. The sum of squares is performed into
contributions from the polynomial model and the experimental value and was calculated by the
following equation (5):
‫ݏݏ‬௙ =
ே
ே೙೑
∑ ሺ‫ݕ‬పഥ − ‫ݕ‬തሻଶ
ே೙೑
௜ୀଵ
(5)
The mean square is the ratio of sum of squares to degrees of freedom was calculated by the
following equation(6):
‫ܵܯ‬ =
ெௌ೔
஽ி೔
(6)
F-value is the ratio of mean square of regression model to the mean square of the experimental
error was calculated by the following equation(7):
‫ܨ‬ − ‫݁ݑ݈ܽݒ‬ =
ெௌ೔
ெௌ೐ೝೝ೚ೝ
(7)
This analysis was out for a 5 % significance level, i.e., for a 95 % confidence level. The
percentage of each factor contribution (Cont. %) on the total variation, then indicating the degree
of influence on the result, was calculated by the following equation (8) :
ܿ‫.ݐ݊݋‬ % =
ௌௌ೔
ௌௌ೘೚೏
ܺ100(8)
A low P-value indicates statistical significance for the source on the corresponding response. It is
clear from the results of ANOVA that the depth of cut is the dominant factor affecting surface
finish. To understand the hard turning process in terms of surface roughness Ra, mathematical
model is developed using multiple regression method. Ra model is given by equations 1 and 2. Its
coefficient of correlation R2
is 92.80% for AISI D3 steel and 75.87% for AISI H13 steel.
Fig.3a. Ra of AISI D3 Fig.3b. Ra of AISI H13
Fig 1. Scatter plots for actual and predicted values of Ra of AISI D3 and AISI
H13steels
Ra(predicted)
SURFACEROUGHNESS(microns)
1.00.90.80.70.6
1.0
0.9
0.8
0.7
0.6
0.5
Scatterplot of SURFACE ROUGHNESS(microns)
PREDICTED
ACTUAL 1.00.90.80.70.6
1.0
0.9
0.8
0.7
0.6
0.5
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
110
Table.6. Analysis of Variance for surface roughness AISI D3
Source DF Seq SS Adj SS Adj MS F P
Regression 9 5.5737 5.5737 0.6193 14.32 0
Speed(mm/min) 1 0.01166 0.0206 0.0206 0.48 0.506
Feed(mm/rev) 1 2.98608 0.21121 0.21121 4.89 0.049
DoC(mm) 1 0.05293 0.06731 0.06731 1.56 0.241
Speed(mm/min)*Speed(mm/min) 1 0.63689 0.01301 0.01301 0.3 0.595
Feed(mm/rev)*Feed(mm/rev) 1 1.70061 1.50886 1.50886 34.9 0.000
DoC(mm)*DoC(mm) 1 0.00269 0.00269 0.00269 0.06 0.808
Speed(mm/min)*Feed(mm/rev) 1 0.11616 0.11616 0.11616 2.69 0.132
Speed(mm/min)*DoC(mm) 1 0.05249 0.05249 0.05249 1.21 0.296
Feed(mm/rev)*DoC(mm) 1 0.0142 0.0142 0.0142 0.33 0.579
Residual Error 10 0.43233 0.43233 0.04323
Total 19 6.00603
Table.7. Analysis of Variance for surface roughness Ra of AISI H13
Source DF Seq SS Adj SS Adj MS F P
Regression 9 1.33475 1.33475 0.148306 3.49 0.032
Speed(mm/min) 1 0.03405 0.25548 0.255479 6.02 0.034
Feed(mm/rev) 1 0.00213 0.04327 0.043274 1.02 0.336
DoC(mm) 1 0.42271 0.13644 0.136442 3.21 0.103
Speed(mm/min)*Speed(mm/min) 1 0.46601 0.25398 0.253984 5.98 0.034
Feed(mm/rev)*Feed(mm/rev) 1 0.00075 0.00147 0.001474 0.03 0.856
DoC(mm)*DoC(mm) 1 0.00119 0.00119 0.001195 0.03 0.870
Speed(mm/min)*Feed(mm/rev) 1 0.05874 0.05874 0.058739 1.38 0.267
Speed(mm/min)*DoC(mm) 1 0.26846 0.26846 0.268461 6.33 0.031
Feed(mm/rev)*DoC(mm) 1 0.08070 0.08070 0.080702 1.90 0.198
Residual Error 10 0.42444 0.42444 0.042444
Total 19 1.75919
3.3 Contour Plots for Surface Roughness Vs Speed, Feed and Depth of cut.
Contour plots play a very important role in the study of the response surface. By creating contour
plots using software for response surface analysis, the optimum is located by characterizing the
shape of the surface. Circular shaped contour represents the independence of factor effects and
elliptical contours may indicate factor interaction. The contours of AISI D3 and AISI H13
responses are shown in figure.2. (a-f).The surface roughness is clearly shown that minimum
roughness is at low value of feed, because feed is the most influencing factor for surface
roughness. Ra is minimum at low depth of cut and also at low speed.
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
111
Fig.2a.Ra vs Speed andFeed(AISI D3) Fig.2b. Ra vsFeed and Speed(AISI H13)
Fig.2c.Ravs Speed andDOC (AISI D3) Fig.2d. Ra vs Speed and DOC(AISI H13)
Fig.2e.Ra vs DOC and Feed (AISI D3) Fig.2f. Ra vs DOC and Feed (AISI H13)
Fig. 2. Contour plots for AISI D3 and AISI H13
3.4 3 D Surface plots
3D Surface plots of Ra vs. different combinations of cutting parameters are shown in figure 3a,
3c, 3e for AISI D3 and these figures obtained by RSM Fig. 3(a) presents the influences of cutting
speed (Vc) and feed rate (f) on the surface roughness, while the depth of cut (ap) is kept at the
middle level. Fig.3(c) shows the estimated response surface in relation to the cutting speed (Vc)
and depth of cut (ap), while feed rate (f) is kept at the middle level. The effects of the feed rate (f)
and depth of cut (ap) on the surface roughness components are shown in Fig. 3(e), while the
cutting speed (Vc) is kept at the middle level. For each plot, the variables not represented are
held at a constant value (the middle level) for AISI D3. For AISI H13 figures shown in 3b, 3d and
3f.These 3D plots confirm the nodes observed during the principal effects plots analysis.
2.1
1.8
1.5
1.2
0.9
0.9
Speed(m/min)
Feed(mm/rev)
165160155150145
0.10
0.09
0.08
0.07
0.06
0.05
1.11.0
0.9 0.9
0.8 0.8
Speed(m/min)
Feed(mm/rev)
165160155150145
0.10
0.09
0.08
0.07
0.06
0.05
0.85
0.80
0.80
0.80
0.75
0.70
0.65
0.60
Speed(m/min)
Doc(mm)
165160155150145
0.9
0.8
0.7
0.6
0.5
0.4
0.3
1.2
1.0
0.8
0.6
Speed(m/min)
Doc(mm) 165160155150145
0.9
0.8
0.7
0.6
0.5
0.4
0.3
1.8
1.5
1.2
0.9 0.9
Feed(mm/rev)
Doc(mm)
0.100.090.080.070.060.05
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.9
0.8
0.7
0.6
0.5
0.9
0.8
0.7
0.6
0.5
Feed(mm/rev)
Doc(mm)
0.100.090.080.070.060.05
0.9
0.8
0.7
0.6
0.5
0.4
0.3
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
112
Fig.3a. Surface roughness vs Speed and Feed
(AISI D3)
Fig. 3b. Surface roughness vs Speed and Feed
(AISI H13)
Fig.3c. Surface roughness vs Speed and DOC
(AISI D3)
Fig. 3d.Surface roughness vs Depth of cut and
Speed(AISI H13)
Fig.3e. Surface roughness Vs Feed and
Depth of cut(AISI D3)
Fig. 3f.Surface roughness vs Feed and
DOC(AISI H13)
Fig. 3. Surface Plots for AISI D3 and AISI H13
4.Conclusions
The tests of straight turning carried out on AISI D3 and AISI H13 steels treated at 62 HRC,
machined by a mixed ceramic tool enabled us to develop statistical models of surface roughness
criteria.
The results revealthat the feed rate isthe most influencing parameter on surface
roughness, than cutting speed and depth of cut for AISI D3.
Surface roughness AISI H13 is influenced mostly by cutting speed than the other
parameters such as feed rate and depth of cut.
Statistical models deduced defined degree of influence of each machining condition
on surface roughness criteria. These models can also be used for the optimization of
hard turning process. This study confirms that in dry hard turning of AISI D3 and
0.5
1.0
1.5
144144
152
160
144
2.0
0.050
168
0.075
0.100
0.075
Ra A ISI D3 (microns)
Feed(mm/rev)
Speed(m/min)
0.8
1.0
144144
152
160
144
1.2
0.050
168
0.075
0.100
0.075
Ra A ISI H13(microns)
Feed(mm/rev)
Speed(m/min)
0.6
0.7
144
152
160
144
152
0.8
0.9
0.8
0.6
0.4
168
Ra A ISI D3 (micr ons)
Doc(mm)
Speed(m/min)
0.50
0.75
1.00
144
152
160
144
152
1.25
168
0.8
0.6
0.4
0.8
Ra A ISI H 1 3 (microns)
Doc(mm)
Speed(m/min)
0.5
1.0
1.5
0.0500.050
0.075
0.050
2.0
0.4
0.100
0.8
0.6
0.4
0.80.8
Ra A ISI D3 (micr ons)
Doc(mm)
Feed(mm/r ev)
0.4
0.6
0.8
0.0500.050
0.075
0.050
0.8
1.0
0.4
0.100
0.8
0.6
0.4
0.8
Ra A ISI H 1 3 ( micr ons)
Doc(mm)
Feed( mm/r ev)
Ra
Ra
Ra Ra
Ra
Ra
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
113
AISI H13 steels for all cutting conditions tested and found roughness criteria are
close to those obtained in grinding.
The surface roughness values of AISI D3 obtained higher when compared to AISI
H13 for the same cutting conditions.
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machining: grey relational theory approach and ANOVA”. International Journal of Advanced
Manufacturing Technology, Vol.45, p.1068-1086.
[13] Ahilan C., Kumanan S., and Sivakumaran N., 2010, “Application of Grey based Taguchi method in
multi response optimization of turning process”. Advances in Production Engineering &
Management, Vol. 5(3), p. 171- 180.
[14] Tzeng CJ., Lin YH., Yang YK., and Jeng MC.,2009,“Optimization of turning operations with
multiple performance characteristics using the Taguchi method and Grey relational analysis”, Journal
of Materials Processing Technology, Vol.209, p. 2753–2759.
[15] Kazancoglu Y., Esme U., Bayramoglu M., Guven O., and Ozgun S., 2011,“Multi-Objective
Optimization of The Cutting Forces In Turning Operations Using The Grey-Based Taguchi Method”,
Materials and Technology, Vol. 45(2), p. 105–110.
[16] Senthilkumar N., Tamizharasan T., and Anandakrishnan V.,2013, “An ANN approach for predicting
the cutting inserts performances of different geometries in hard turning” Advances in Production
Engineering & Management, Vol. 8(4), p.231-241.
[17] Montgomery, D.C. “Design and Analysis of Experiments”; John Wiley & Sons, Inc: New York,
1997; p. 395-476.
International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015
114
Authors:
1) Varaprasad Bhemuni currently an Assistant. Professor in Mechanical
Engineering Department at GVP Degree and PG Courses (Technical Campus), School of
Engineering, Rushikonda, Visakhapatnam. He has more than 10 years teaching
experience and worked at different positions. He has life member of many technical
societies.
2) Chalamalasetti Srinivasa Rao is currently Professor in the Department of
Mechanical Engineering, Andhra University, Visakhapatnam, India. He graduated in
Mechanical Engineering from SVH Engineering College, Machilipatnam, India in
1988. He received his Master’s Degree from MANIT, Bhopal, India in 1991. He
received PhD from Andhra University in 2004.He has published over 100 research
papers in refereed journals and conference proceedings.

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COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD TURNING

  • 1. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 DOI : 10.14810/ijmech.2015.4109 105 COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD TURNING Varaprasad.Bh1* , Srinivasa Rao.Ch2 1* Mechanical Engineering Department, GVP College for Degree and P.G. Courses, School of Engineering (Technical Campus), Rushikonda, Visakhapatnam, India 2 Mechanical Engineering Department, Andhra University, College of Engineering (A) Visakhapatnam, India. ABSTRACT The hard turning process has been attracting interest in different industrial sectors for finishing operations of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate and depth of cut are investigated for main performance characteristic that is surface roughness. RSM based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting speed; feed rate and depth of cut are investigated using surface plots. Key words: Hard turning, Surface Roughness, AISI D3, AISI H13, RSM and ANOVA. 1. INTRODUCTION Hard turning is the process of single point cutting of hardened ferrous material with a hardness value more than 45HRC in order to obtain finished workpieces directly from hardened parts [1- 5]. Hardened steels are most widely used in multiple industrial applications like automotive, aeronautics, tool design and mold design.Many industrial steel components under influence of critical loads from automotive and aerospace parts to bearing and forming tool are made of hardened steel. These parts are normally finished by grinding, which is time consuming and costly. For this reason, hard turning has become the most important substitute to grinding for hardened steels [6, 7].With advent of new kind of tools such as Cubic Boron Nitride (CBN), Polycrystalline Cubic Boron Nitride (PCBN), poly-crystalline diamond (PCD), coated, Chemical Vapor Deposition (CVD), Physical Vapor Deposition (PVD) and ceramic tools, better surface finish will be accessible without any finishing and complementary operation such as grinding. Reduction in machining costs, elimination of cutting fluids, increase in the flexibility and efficiency, reduction in part-handling costs and finally decrease in the set-up times when compared to grinding process are the advantages of hard turning [1,4]. Achieving better surface quality, tool life and dimensional accuracy are of crucial concerns in turning of hardened steels [4]. The major focus of present research is on surface roughness of the machined surfaces and it is one of the most important product quality characteristics. Achieving the suitable surface quality
  • 2. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 106 in hard turning especially in comparison with grinding is of great importance to the functional behavior of a machined part. Very few studies are reported on hard turning of AISI D3 with ceramic tool and also comparison of machining of both AISI D3 and AISI H13. The main scope of the present research is the experimental investigation of the effect of machining parameters (i.e., cutting speed, feed rate, depth of cut) on surface roughness in hard turning process of AISI D3 and AISI H13. In this experimental work, ANOVA is used to know the percentage of contribution of each parameter on performance. To analyze the effect of process parameters on surface roughness by plotting main effects graph and their individual interactions. Moreover, RSM and regression analysis are used to establish the correlation between factors and responses. Al2O3/TiN-coated tungsten carbide tools for finish-turning of NiCr20TiAl nickel-based alloy under various cutting conditions, cutting forces, surface integrity and tool wear are investigated and the inter-diffusing and transferring of elements between Al2O3/TiN-coated tungsten carbide tool and NiCr20TiAl nickel-based alloy are studied [8]. Investigated the cutting performance of tungsten carbide tools with restricted contact length and multilayer chemical vapor deposition coatings, TiCN/Al2O3/TiN and TiCN/Al2O3–TiN in dry turning of AISI 4140 and the results show that coating layouts and cutting tool edge geometry can significantly affect heat distribution into the cutting tool [9]. Presented an optimization method of the machining parameters in high-speed machining of stainless steel using coated carbide tool to achieve minimum cutting forces and better surface roughness using Taguchi’s technique and pareto ANOVA and found that the feed rate is found to be more significant followed by the cutting speed and the depth of cut [10]. A method developed to identify surface roughness based on measurement of workpiece surface temperature and root mean square for feed vibration of the cutting tool during turning mild steel using grey relational analysis [11]. Machinability of hardened steel using grey relational approach and ANOVA to obtain optimum process parameters considering MRR, surface finish, tool wear and tool life for both rough and finish machining [12]. Multi-response optimization of turning parameters and nose radius over surface roughness and power consumed using Taguchi based grey relational approach and found that the main influencing parameter is cutting speed followed by feed rate and depth of cut [13]. In turning operations, for multi-response optimization Taguchi based grey relational approach is used to identify the optimum conditions to obtain better results [14, 15]. Prediction of flank wear and surface roughness during hard turning is performed using uncoated carbide inserts of various tool geometries [16]. 2. Experimentation The materials used for experiments are AISI D3 and AISI H13. Bars of diameter 70 mm x 360 mm long are prepared. Test sample is trued, centred and cleaned by removing a 2 mm layer prior to actual machining tests. The chemical composition of the work piece materials are given in Table.1 and Table.2.The AISI D3 is oil-quenched from 980o C (1800o F) for hardening, followed by tempering at 200o C to attain 62HRC. The AISI H13 is hardened by oil quenching from 1050o C and tempered at 600o C to attain 62 HRC. Table.1 Chemical composition of AISI D3 (wt%) C Si Mn P S Cr Ni Mo Al Cu Zn Fe 2.06 0.55 0.449 0.036 0.056 11.09 0.277 0.207 0.0034 0.13 0.27 84.8716 Table.2 Chemical composition of AISI H13 (wt%) C Si Mn P S Cr Ni Mo V Fe 0.4 1.05 0.35 0.03 0.003 5.03 0.3 1.4 1.0 90.437
  • 3. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 107 The lathe used for machining operations is Kirloskar; model Turn Master-35, spindle power 6.6KW.Surface roughness is measured using MitutoyoSurftest SJ 210 having measuring range of 17.5mm and skid force less than 400 mN. Four readings with a sample length of 0.8 mm are recorded after each experiment and an average value is taken as the surface roughness. These values are obtained without disturbing the assembly of the workpiece in order to reduce uncertainties. The cutting insert used is a mixed ceramic removable, of square form with eight cutting edges and having designation SNGA 120408 T01020 (Sandvik make CC6050) is a mixed ceramic grade based on alumina with an addition of titanium carbide. The high hot-hardness, the good level of toughness makes the grade suitable as first choice for machining hardened steels (50 – 65HRC) in applications with good stability or with light interrupted cuts. The inserts are mounted on a commercial tool holder of designation PSBNR 2525 M 12 (ISO) with the geometry of active part characterized by the following angles: χ = 75°; α = 6°; γ = −6°; λ = −6°. Three levels are defined for each cutting variable as given in Table.3. The variable levels are chosen within the intervals according to recommendations made by the cutting tool manufacturer. Three selected cutting variables at three levels led to a total of 20 tests. Table.3. Assignment of the levels to the variables Parameters Range -1 0 +1 Speed(m/min) 145 155 165 Feed(mm/rev) 0.05 0.075 0.1 Depth of cut(mm) 0.3 0.6 0.9 3. ANALYSIS OF RESULTS The analysis is made by considering experimental results of surface roughness (Ra) for various combinations of cutting conditions (cutting speed, feed rate and depth of cut) as per the design matrix. Data is analyzed statistically usingANOVA, Contour plots and Surface plots are shown and discussed in the following sections. 3.1 Statistical Analysis In RSM, the quantitative form of the relationship between the desired response and independent input process parameters can be represented by [17]. ܻ = ∅൫ܸ௖, ݂, ܽ௣൯ (1) Where Y is the desired response and f is the response function. In the present investigation, the RSM-based mathematical model for surface roughness Ra, has been developed with cutting speed Vc, feed rate f and depth of cut ap as the process parameters. The response surface equation for three factors is given by [17]. ܻ = ܽ଴ + ܽଵܸ௖ + ܽଶ݂ + ܽଷܽ௣ + ܽଵଶܸ௖݂ + ܽଵଷܸ௖ܽ௣ + ܽଶଷ݂ܽ௣ + ܽଵଵܸ௖ ଶ + ܽଶଶ݂ଶ + ܽଷଷܽ௣ ଶ (2) Where Y; desired response and a1,............, a33; regression coefficients to be determined for each response. The estimated Regression Coefficients for surface roughness of AISI D3 and AISI H13 for surface roughness Ra are shown in Table.4 and 5.
  • 4. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 108 Table.4. Estimated Regression Coefficients for surface roughness of AISI D3Ra (microns) ܴ௔ = −16.55 + 0.27 × ܺଵ − 121.55 × ܺଶ + 5.27 × ܺଷ + 1185.16 × ܺଶ ଶ (3) Where ܺଵ, ܺଶ and ܺଷSpeed, Feed and Depth of cut. Table.5. Estimated Regression Coefficients for surface roughness of AISI H13 Ra(microns) ܴ௔ = 73.66 − 0.94 × ܺଵ + 55.02 × ܺଶ − 7.49 × ܺଷ + 0.003 × ܺଵ ଶ + 0.0611 × ሺܺଵ × ܺଶሻ (4) Whereܺଵ is Speed, ܺଶ is Feed and ܺଷ is Depth of cut. Scatter plots identifies the relationship between two variables whether the relationship is positive, negative, or no relationship can be easily detected. It can be observed from figure.1 the residuals are located on straight line, which means that the errors are distributed normally. Hence the developed empirical models can represent the process significantly. Therefore these models can be further used for optimization of process parameters such as speed, feed and depth of cut. Term Coef SE Coef T P Remarks Constant -16.55 29.814 -0.555 0.591 Insignificant Speed(m/min) 0.27 0.39 0.69 0.506 Insignificant Feed(mm/rev) -121.55 54.994 -2.21 0.049 Significant DOC(mm) 5.27 4.22 1.248 0.241 Insignificant Speed(m/min) x Speed(m/min) 0 0.001 -0.548 0.595 Insignificant Feed(mm/rev) x Feed(mm/rev) 1185.16 200.614 5.908 0.000 Significant DOC(mm) x DOC(mm) -0.35 1.393 -0.249 0.808 Insignificant Speed(m/min) x Feed(mm/rev) -0.48 0.294 -1.639 0.132 Insignificant Speed(m/min) x DOC(mm) -0.03 0.025 -1.102 0.296 Insignificant Feed(mm/rev) x DOC(mm) -5.62 9.802 -0.573 0.579 Insignificant S = 0.207925 PRESS = 2.99659 R-Sq = 92.80% R-Sq(pred) = 50.11% R-Sq(adj) = 86.32% Term Coef SE Coef T P Remarks Constant 73.6655 29.541 2.494 0.032 Significant Speed(m/min) -0.9472 0.386 -2.453 0.034 Significant Feed(mm/rev) 55.0202 54.49 1.01 0.336 Insignificant DOC(mm) -7.497 4.181 -1.793 0.103 Insignificant Speed(m/min) x Speed(m/min) 0.003 0.001 2.446 0.034 Significant Feed(mm/rev) x Feed(mm/rev) 37.0473 198.776 0.186 0.856 Insignificant DOC(mm) x DOC(mm) -0.2316 1.38 -0.168 0.87 Insignificant Speed(m/min) x Feed(mm/rev) -0.3428 0.291 -1.176 0.267 Insignificant Speed(m/min) x DOC(mm) 0.0611 0.024 2.515 0.031 Significant Feed(mm/rev) x DOC(mm) -13.3917 9.712 -1.379 0.198 Insignificant S = 0.206020 PRESS = 6.78960 R-Sq = 75.87% R-Sq(pred) = 0.00% R-Sq(adj) = 54.16%
  • 5. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 109 3.2 Analysis of Variance It is clear from the results of ANOVA that the feed is the dominant factor affecting surface finish Ra. The second factor influencing Ra is cutting speed x feed for AISI D3 shown in table.6. Table.7.shown below is ANOVA for AISI H13.To understand the hard turning process in terms of surface roughness Ra, mathematical modelsare developed using multiple regression method. Ra models are given by equations (3&4). Its coefficient of correlation R2 is 92.8 for AISI D3 and its value 75.87 for AISI H13. The ANOVA has been applied to check the adequacy of the developed models. The ANOVA table consists of sum of squares and degrees of freedom. The sum of squares is performed into contributions from the polynomial model and the experimental value and was calculated by the following equation (5): ‫ݏݏ‬௙ = ே ே೙೑ ∑ ሺ‫ݕ‬పഥ − ‫ݕ‬തሻଶ ே೙೑ ௜ୀଵ (5) The mean square is the ratio of sum of squares to degrees of freedom was calculated by the following equation(6): ‫ܵܯ‬ = ெௌ೔ ஽ி೔ (6) F-value is the ratio of mean square of regression model to the mean square of the experimental error was calculated by the following equation(7): ‫ܨ‬ − ‫݁ݑ݈ܽݒ‬ = ெௌ೔ ெௌ೐ೝೝ೚ೝ (7) This analysis was out for a 5 % significance level, i.e., for a 95 % confidence level. The percentage of each factor contribution (Cont. %) on the total variation, then indicating the degree of influence on the result, was calculated by the following equation (8) : ܿ‫.ݐ݊݋‬ % = ௌௌ೔ ௌௌ೘೚೏ ܺ100(8) A low P-value indicates statistical significance for the source on the corresponding response. It is clear from the results of ANOVA that the depth of cut is the dominant factor affecting surface finish. To understand the hard turning process in terms of surface roughness Ra, mathematical model is developed using multiple regression method. Ra model is given by equations 1 and 2. Its coefficient of correlation R2 is 92.80% for AISI D3 steel and 75.87% for AISI H13 steel. Fig.3a. Ra of AISI D3 Fig.3b. Ra of AISI H13 Fig 1. Scatter plots for actual and predicted values of Ra of AISI D3 and AISI H13steels Ra(predicted) SURFACEROUGHNESS(microns) 1.00.90.80.70.6 1.0 0.9 0.8 0.7 0.6 0.5 Scatterplot of SURFACE ROUGHNESS(microns) PREDICTED ACTUAL 1.00.90.80.70.6 1.0 0.9 0.8 0.7 0.6 0.5
  • 6. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 110 Table.6. Analysis of Variance for surface roughness AISI D3 Source DF Seq SS Adj SS Adj MS F P Regression 9 5.5737 5.5737 0.6193 14.32 0 Speed(mm/min) 1 0.01166 0.0206 0.0206 0.48 0.506 Feed(mm/rev) 1 2.98608 0.21121 0.21121 4.89 0.049 DoC(mm) 1 0.05293 0.06731 0.06731 1.56 0.241 Speed(mm/min)*Speed(mm/min) 1 0.63689 0.01301 0.01301 0.3 0.595 Feed(mm/rev)*Feed(mm/rev) 1 1.70061 1.50886 1.50886 34.9 0.000 DoC(mm)*DoC(mm) 1 0.00269 0.00269 0.00269 0.06 0.808 Speed(mm/min)*Feed(mm/rev) 1 0.11616 0.11616 0.11616 2.69 0.132 Speed(mm/min)*DoC(mm) 1 0.05249 0.05249 0.05249 1.21 0.296 Feed(mm/rev)*DoC(mm) 1 0.0142 0.0142 0.0142 0.33 0.579 Residual Error 10 0.43233 0.43233 0.04323 Total 19 6.00603 Table.7. Analysis of Variance for surface roughness Ra of AISI H13 Source DF Seq SS Adj SS Adj MS F P Regression 9 1.33475 1.33475 0.148306 3.49 0.032 Speed(mm/min) 1 0.03405 0.25548 0.255479 6.02 0.034 Feed(mm/rev) 1 0.00213 0.04327 0.043274 1.02 0.336 DoC(mm) 1 0.42271 0.13644 0.136442 3.21 0.103 Speed(mm/min)*Speed(mm/min) 1 0.46601 0.25398 0.253984 5.98 0.034 Feed(mm/rev)*Feed(mm/rev) 1 0.00075 0.00147 0.001474 0.03 0.856 DoC(mm)*DoC(mm) 1 0.00119 0.00119 0.001195 0.03 0.870 Speed(mm/min)*Feed(mm/rev) 1 0.05874 0.05874 0.058739 1.38 0.267 Speed(mm/min)*DoC(mm) 1 0.26846 0.26846 0.268461 6.33 0.031 Feed(mm/rev)*DoC(mm) 1 0.08070 0.08070 0.080702 1.90 0.198 Residual Error 10 0.42444 0.42444 0.042444 Total 19 1.75919 3.3 Contour Plots for Surface Roughness Vs Speed, Feed and Depth of cut. Contour plots play a very important role in the study of the response surface. By creating contour plots using software for response surface analysis, the optimum is located by characterizing the shape of the surface. Circular shaped contour represents the independence of factor effects and elliptical contours may indicate factor interaction. The contours of AISI D3 and AISI H13 responses are shown in figure.2. (a-f).The surface roughness is clearly shown that minimum roughness is at low value of feed, because feed is the most influencing factor for surface roughness. Ra is minimum at low depth of cut and also at low speed.
  • 7. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 111 Fig.2a.Ra vs Speed andFeed(AISI D3) Fig.2b. Ra vsFeed and Speed(AISI H13) Fig.2c.Ravs Speed andDOC (AISI D3) Fig.2d. Ra vs Speed and DOC(AISI H13) Fig.2e.Ra vs DOC and Feed (AISI D3) Fig.2f. Ra vs DOC and Feed (AISI H13) Fig. 2. Contour plots for AISI D3 and AISI H13 3.4 3 D Surface plots 3D Surface plots of Ra vs. different combinations of cutting parameters are shown in figure 3a, 3c, 3e for AISI D3 and these figures obtained by RSM Fig. 3(a) presents the influences of cutting speed (Vc) and feed rate (f) on the surface roughness, while the depth of cut (ap) is kept at the middle level. Fig.3(c) shows the estimated response surface in relation to the cutting speed (Vc) and depth of cut (ap), while feed rate (f) is kept at the middle level. The effects of the feed rate (f) and depth of cut (ap) on the surface roughness components are shown in Fig. 3(e), while the cutting speed (Vc) is kept at the middle level. For each plot, the variables not represented are held at a constant value (the middle level) for AISI D3. For AISI H13 figures shown in 3b, 3d and 3f.These 3D plots confirm the nodes observed during the principal effects plots analysis. 2.1 1.8 1.5 1.2 0.9 0.9 Speed(m/min) Feed(mm/rev) 165160155150145 0.10 0.09 0.08 0.07 0.06 0.05 1.11.0 0.9 0.9 0.8 0.8 Speed(m/min) Feed(mm/rev) 165160155150145 0.10 0.09 0.08 0.07 0.06 0.05 0.85 0.80 0.80 0.80 0.75 0.70 0.65 0.60 Speed(m/min) Doc(mm) 165160155150145 0.9 0.8 0.7 0.6 0.5 0.4 0.3 1.2 1.0 0.8 0.6 Speed(m/min) Doc(mm) 165160155150145 0.9 0.8 0.7 0.6 0.5 0.4 0.3 1.8 1.5 1.2 0.9 0.9 Feed(mm/rev) Doc(mm) 0.100.090.080.070.060.05 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.9 0.8 0.7 0.6 0.5 0.9 0.8 0.7 0.6 0.5 Feed(mm/rev) Doc(mm) 0.100.090.080.070.060.05 0.9 0.8 0.7 0.6 0.5 0.4 0.3
  • 8. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 112 Fig.3a. Surface roughness vs Speed and Feed (AISI D3) Fig. 3b. Surface roughness vs Speed and Feed (AISI H13) Fig.3c. Surface roughness vs Speed and DOC (AISI D3) Fig. 3d.Surface roughness vs Depth of cut and Speed(AISI H13) Fig.3e. Surface roughness Vs Feed and Depth of cut(AISI D3) Fig. 3f.Surface roughness vs Feed and DOC(AISI H13) Fig. 3. Surface Plots for AISI D3 and AISI H13 4.Conclusions The tests of straight turning carried out on AISI D3 and AISI H13 steels treated at 62 HRC, machined by a mixed ceramic tool enabled us to develop statistical models of surface roughness criteria. The results revealthat the feed rate isthe most influencing parameter on surface roughness, than cutting speed and depth of cut for AISI D3. Surface roughness AISI H13 is influenced mostly by cutting speed than the other parameters such as feed rate and depth of cut. Statistical models deduced defined degree of influence of each machining condition on surface roughness criteria. These models can also be used for the optimization of hard turning process. This study confirms that in dry hard turning of AISI D3 and 0.5 1.0 1.5 144144 152 160 144 2.0 0.050 168 0.075 0.100 0.075 Ra A ISI D3 (microns) Feed(mm/rev) Speed(m/min) 0.8 1.0 144144 152 160 144 1.2 0.050 168 0.075 0.100 0.075 Ra A ISI H13(microns) Feed(mm/rev) Speed(m/min) 0.6 0.7 144 152 160 144 152 0.8 0.9 0.8 0.6 0.4 168 Ra A ISI D3 (micr ons) Doc(mm) Speed(m/min) 0.50 0.75 1.00 144 152 160 144 152 1.25 168 0.8 0.6 0.4 0.8 Ra A ISI H 1 3 (microns) Doc(mm) Speed(m/min) 0.5 1.0 1.5 0.0500.050 0.075 0.050 2.0 0.4 0.100 0.8 0.6 0.4 0.80.8 Ra A ISI D3 (micr ons) Doc(mm) Feed(mm/r ev) 0.4 0.6 0.8 0.0500.050 0.075 0.050 0.8 1.0 0.4 0.100 0.8 0.6 0.4 0.8 Ra A ISI H 1 3 ( micr ons) Doc(mm) Feed( mm/r ev) Ra Ra Ra Ra Ra Ra
  • 9. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 113 AISI H13 steels for all cutting conditions tested and found roughness criteria are close to those obtained in grinding. The surface roughness values of AISI D3 obtained higher when compared to AISI H13 for the same cutting conditions. References [1] Özel, T., and Karpat, Y., 2005, “Predictive Modeling of Surface Roughness and Tool Wear in Hard Turning Using Regression and Neural Networks”, International Journal of Machine Tools and Manufacture, Vol.45, p.467-479. [2] Zeren, E., and Özel, T,2002, “Hard Turning Technology”, Report No. MARL-01, Rutgers, The State University of New Jersey. [3] Koenig, W., Berktold, A., and Koch, F., 1993, “Turning Versus Grinding-A Comparison of Surface Integrity Aspects and Attainable Accuracies”, Annals of the CIRP, Vol. 42(1), p. 39- 43. [4] Mohammadi,A. and Zarepour,H., 2008, “Statistical Analysis Of Hard turning Of AISI 4340 Steel on surface finish and Cutting Region Temperature” ,M0048010,Bahrain ,Manama, AMPT 2008. [5] Kountanya, R.K., 2008, “Optimizing PCBN cutting tool performance in hard turning” ,Proceeding of the Institution of Mechanical Engineers, part B:Journal of Engineerin manufacture, Vol. 222, p. 969- 980. [6] Dogra,M., Sharma,V.S., Sachdeva,A., Mohan suri,N. and Dureja,J.S, 2010, “Tool wear, Chip Formation and Workpiece Surface Issues In CBN Hard Turning:A Review”, Intetnational Journal of Pecision Engineering and Manufacturing,Vol.11,p. 341-358. [7] Horng,J-T., Liu,N-M., Chiang, K-T., 2008, “Investigating the machinability evaluation of hodfield steel in the hard turning with Al2O3/TiC mixed ceramic Tool based on the response surface methodology”, Journal Of Materials Processing Technology, Vol. 208,p. 532-541. [8] Zou B., Chen M., and Li S., 2011, “Study on finish-turning of NiCr20TiAl nickel-based alloy using Al2O3/TiNcoated carbide tools”. International Journal of Advanced Manufacturing Technology, Vol.53, p.81–92 [9] Fahad M., Mativenga PT., and Sheikh MA., 2012,“A comparative study of multilayer and functionally graded coated tools in high-speed machining”, International Journal of Advanced Manufacturing Technology, Vol. 62, p. 43–57. [10] Hamdan A., Sarhan AAD., and Hamdi M., 2012, “An optimization method of the machining parameters in high speed machining of stainless steel using coated carbide tool for best surface finish”, International Journal of Advanced Manufacturing Technology,Vol. 58, p.81–91. [11] Suhail AH., Ismail N., Wong SV., and Jalil NAA., 2012,“Surface Roughness Identification Using the Grey Relational Analysis with Multiple Performance Characteristics in Turning operations”, The Arabian Journal for Science and Engineering, Vol.37(4), p. 1111-1117 [12] Gopalsamy BM., Mondal B., and Ghosh S., 2009, “Optimisation of machining parameters for hard machining: grey relational theory approach and ANOVA”. International Journal of Advanced Manufacturing Technology, Vol.45, p.1068-1086. [13] Ahilan C., Kumanan S., and Sivakumaran N., 2010, “Application of Grey based Taguchi method in multi response optimization of turning process”. Advances in Production Engineering & Management, Vol. 5(3), p. 171- 180. [14] Tzeng CJ., Lin YH., Yang YK., and Jeng MC.,2009,“Optimization of turning operations with multiple performance characteristics using the Taguchi method and Grey relational analysis”, Journal of Materials Processing Technology, Vol.209, p. 2753–2759. [15] Kazancoglu Y., Esme U., Bayramoglu M., Guven O., and Ozgun S., 2011,“Multi-Objective Optimization of The Cutting Forces In Turning Operations Using The Grey-Based Taguchi Method”, Materials and Technology, Vol. 45(2), p. 105–110. [16] Senthilkumar N., Tamizharasan T., and Anandakrishnan V.,2013, “An ANN approach for predicting the cutting inserts performances of different geometries in hard turning” Advances in Production Engineering & Management, Vol. 8(4), p.231-241. [17] Montgomery, D.C. “Design and Analysis of Experiments”; John Wiley & Sons, Inc: New York, 1997; p. 395-476.
  • 10. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.1, February 2015 114 Authors: 1) Varaprasad Bhemuni currently an Assistant. Professor in Mechanical Engineering Department at GVP Degree and PG Courses (Technical Campus), School of Engineering, Rushikonda, Visakhapatnam. He has more than 10 years teaching experience and worked at different positions. He has life member of many technical societies. 2) Chalamalasetti Srinivasa Rao is currently Professor in the Department of Mechanical Engineering, Andhra University, Visakhapatnam, India. He graduated in Mechanical Engineering from SVH Engineering College, Machilipatnam, India in 1988. He received his Master’s Degree from MANIT, Bhopal, India in 1991. He received PhD from Andhra University in 2004.He has published over 100 research papers in refereed journals and conference proceedings.