Abstract
Hard turning is a manufacturing process widely used in aerospace industries. The effect of hard turning on the surface integrity is mainly influenced by the choice of the process parameters. The aim of this paper is to present an exhaustive study for optimizing the hard turning process parameters using the response surface methodology (RSM) coupled with the finite element method. In particular, a case study is developed where AISI 52100 (62 HRc) is machined by PCBN tool. For this purpose, a finite element model (FEM) of orthogonal cutting is developed by the software ABAQUS. In this study, empirical models of machining forces and white layers (WL) thickness are developed. The empirical models have been determined using the RSM, in which three factors with three levels are implemented. The cutting speed, the feed rate, and the depth of cut are considered as the main input parameters. The analysis of variance (ANOVA) was also employed in order to analyze the effects and interactions of the cutting parameters on the performance of machined parts. Lastly, the optimum parametric combination is determined to allow the minimization of machining forces and WL thickness. The proposed approach can be considered as a helpful method for engineering design to optimize hard turning parameters.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Ventura CE, Breidenstein B, Denkena B (2017) Influence of customized cutting edge geometries on the workpiece residual stress in hard turning. Proc Inst Mech Eng B J Eng Manuf, p. 95440541668538.
Zhao T, Zhou JM, Bushlya V, Stahl JE (2017) Effect of cutting edge radius on surface roughness and tool wear in hard turning of AISI 52100 steel. Int J Adv Manuf Technol:1–8
Shalaby MA, El Hakim MA, Veldhuis SC, Dosbaeva GK (2017) An investigation into the behavior of the cutting forces in precision turning. Int J Adv Manuf Technol 90(5–8):1605–1615
Chen T, Qiu C, Liu X, Qian X, Liu G (2017) Study on test method of white layer microhardness in hard cutting based on chord tangent method. Int J Adv Manuf Technol
Yan H, Hua J, Shivpuri R (2005) Numerical simulation of finish hard turning for AISI H13 die steel. Sci Technol Adv Mater 6(5):540–547
Gaitonde VN, Karnik SR, Figueira L, Paulo Davim J (2009) Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts. Int J Refract Met Hard Mater 27(4):754–763
Zhang X-M, Chen L, Ding H (2016) Effects of process parameters on white layer formation and morphology in hard turning of AISI52100 steel. J Manuf Sci Eng 138(7):74502
Arfaoui S, Zemzemi F, Tourki Z (2018) A numerical-analytical approach to predict white and dark layer thickness of hard machining. Int J Adv Manuf Technol, https://doi.org/10.1007/s00170-018-1831-2
Saini S, Ahuja IS, Sharma VS (2012) Influence of cutting parameters on tool wear and surface roughness in hard turning of AISI H11 tool steel using ceramic tools. Int J Precis Eng Manuf 13(8):1295–1302
Das SR, Dhupal D, Kumar A (2015) Study of surface roughness and flank wear in hard turning of AISI 4140 steel with coated ceramic inserts. J Mech Sci Technol 29(10):4329–4340
Lalwani DI, Mehta NK, Jain PK (2008) Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel. J Mater Process Technol 206(1–3):167–179
Bouacha K, Yallese MA, Mabrouki T, Rigal JF (2010) Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool. Int J Refract Met Hard Mater 28(3):349–361
Özel T, Hsu TK, Zeren E (2005) 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(3–4):262–269
Kartal ME, Başaĝa HB, Bayraktar A (2011) Probabilistic nonlinear analysis of CFR dams by MCS using response surface method. Appl Math Model 35(6):2752–2770
Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21(1):31–48
Duan C, Kong W, Hao Q, Zhou F (2013) Modeling of white layer thickness in high speed machining of hardened steel based on phase transformation mechanism. Int J Adv Manuf Technol 69(1–4):59–70
Shi J, Liu CR (2006) On predicting chip morphology and phase transformation in hard machining. Int J Adv Manuf Technol 27(7–8):645–654
Zhang X, Wu S, Wang H, Liu CR (2011) Predicting the effects of cutting parameters and tool geometry on hard turning process using finite element method. J Manuf Sci Eng 133(4):41010
Din SKS, Ricottura FN, Rinvenimento T Comparable standards. pp. 91–92.
Ramesh A, Melkote SN (2008) Modeling of white layer formation under thermally dominant conditions in orthogonal machining of hardened AISI 52100 steel. Int J Mach Tools Manuf 48(3–4):402–414
Hua J, Umbrello D, Shivpuri R (2006) Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel. J Mater Process Technol 171(2):180–187
Chou YK, Song H (2005) Thermal modeling for white layer predictions in finish hard turning. Int J Mach Tools Manuf 45(4–5):481–495
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Arfaoui, S., Zemzemi, F., Dakhli, M. et al. Optimization of hard turning process parameters using the response surface methodology and finite element simulations. Int J Adv Manuf Technol 103, 1279–1290 (2019). https://doi.org/10.1007/s00170-019-03535-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-03535-2