International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 04 | Apr -2017
p-ISSN: 2395-0072
www.irjet.net
EFFECT OF COATING THICKNESS WITH CARBIDE TOOL IN HARD TURNING OF AISID3 COLD WORK STEEL Gurjeet Singh1, Harjit Singh2, Jatinder Kumar3 Research Scholar, Mechanical Engg. Dept, CTIEMT Jalandhar, Punjab, India. 144001 Assistant Professor, Mechanical Engg. Dept., CTIEMT Jalandhar, Punjab, India. 144001 3 Assistant Professor, Mechanical Engg. Dept., SSIET Jalandhar, Punjab, India. 144001
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Abstract - In modern days, turning process plays an
essential role among material removal techniques. The cutting parameters and tool configuration plays as essential role in turning as these parameters decide the cost and time of process and in turn the quality of the product. The researchers have considered numerous aspects in turning of hard materials. In the present study, under unstable machining conditions the performance of multilayer coated carbide inserts with different thicknesses was experimentally investigated using a Taguchi L18 OA. The TiN/TiCN/Al2O3/TiN multi-layer coated inserts with different thickness are used for turning AISI D3 Die steel. Taguchi’s mixed level Design of Experiments (DoE) is used to perform the experiments. The significance of the process parameters was evaluated using analysis of variance (ANOVA). Experiments were conducted on conventional turning centre and output responses like surface roughness and Material Removal Rate (MRR) are determined. For multi-response optimization, initially Signal-to-Noise (S/N) ratio is calculated and is applied to simultaneously optimize the output responses. Key Words: Multilayer coated inserts, Taguchi Method, AISI D3.
1. INTRODUCTION Turning is a process of removing unwanted material from a rotating work piece to obtain a desired shape and size of component. Hard turning deals with turning materials with a hardness of above 45 HRC, typically in the hardness range of 58 to 68 HRC [1]. Hard turning operation is performed with coated carbide, cermet, ceramic, PcBN and PCD tools. In recent years, application of single-layer coated and multilayered coated cutting tools are used for machining hardened materials to improve the tribological conditions at the tool-workpiece interface and at the tool-chip interface. In these days, the manufacturers are more concentrate on final product accuracy and quality rather than tool wear or cutting force [18]. Today 85% of carbide cutting inserts used in industry are coated, to obtain better results and great number of coating materials and methods are also available. By practical approach the type of tool wear mechanism should be identified and a suitable coating on cutting insert has to be selected by correlating the coating materials and their performance before choosing a cutting insert [2]. Š 2017, IRJET
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Coating does change the dimensions of the cutting tool. Coatings are often applied in multiple alternating layers since the hardness increases as its grain size decreases. Varaprasad et al. [1] optimized several machining parameters to minimize tool wear during the turning of AISI D3 steel with different Al2O3/TiC mixed ceramic tools. Similarly Varaprasad et al. [2] investigated the effect of machining parameters on tool wear and nodal temperature during turning of same material using CC6050 ceramic inserts, and reported that the RSM design is an effective way of determining the optimal cutting parameters for achieving low tool wear and low Nodal temperature. Dureja et al. [3] reported cutting speed and federate are significant parameters to minimize tool wear and roughness in turning AISI D3 using TiSiN-TiAlN coated carbide tools. Senthilkumar et al. [4] used hybrid Taguchi-Grey relational technique and cuckoo search algorithm for multi-criteria optimization in hard turning AISI D3. Alaattin Kacal et al. [5] conducted experiments on high speed turning of AISI S1 (60WCrV8) Cold Work Tool Steel with ceramic and CBN cutting tools. Results revealed that CBN cutter exhibited a better performance than the ceramic cutter. Bouchelaghem et al. [6] Experimental investigation and Performance analysis of CBN insert in hard turning of cold work tool steel (D3). The results indicated that CBN is resistant to wear despite of aggressiveness of AISI D3 steel. Wang [7] investigated the effect of the multi-layer hard surface coating of cutting tools on the cutting forces in steel turning with different commercially available carbide inserts and tool geometries over a range of cutting conditions. Bouzakis et al. [8] worked on failure mechanism of physically vapor deposited TiAlN coated hard metal cutting inserts in turning. The results show that a progressive local coating decomposition occurs while the cutting forces remain practically stable. Li et al. [9] studied the tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts. The experimental result showed that significant flank wear was the predominant failure mode affecting the tool life. More et al. [10] experimented and analyzed the effect of cutting speed and feed rate on tool wear, surface roughness and cutting forces of the CBN-TiN coated carbide inserts in turning AISI4340 hardened steel. Quian et al. [11] performed numerical simulation of high speed orthogonal machining to study the finish hard turning process as a function of cutting speed, feed, cutter geometry, and work piece hardness using AISI 52100 bearing steel AISI
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