Abstract
This paper presents a comparison of surface roughness between both ceramic cutting tools namely, TiN coated mixed ceramic CC6050 and uncoated mixed ceramic CC650 when machining hardened hot work steel X38CrMoV5-1 [AISI H11] treated at 50 HRC. A mathematical model, relating surface roughness criteria and main factors such as cutting radius, cutting speed, feed rate, and depth of cut, was developed using response surface methodology (RSM) and its adequacy was checked by regression analysis. The effect of cutting parameters on surface roughness is evaluated and the optimum cutting conditions to minimize the surface roughness are determined. A multiple linear models have been established between the cutting parameters and the surface roughness using response surface methodology. The experimental results reveal that the most significant machining parameter for surface roughness is the feed followed by cutting radius. Also the determined optimal conditions really reduce the surface roughness on the machining of AISI H11 steels within the ranges of parameters studied. In addition, excellent surface roughness was obtained in hard turning using CC650 tools. The coated ceramic tools had no advantage over CC650 from the point of view of surface roughness.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Aouici H, Yallese MA, Elbah M, Fnides B, Chaoui K, Mabrouki T (2011) Modeling and optimization of hard turning of X38CrMoV5-1 steel with CBN tool: machining parameters effects on flank wear and surface roughness. J Mech Sci Technol 25(11):2843–2851
Aouici H, Bouchelaghem H, Yallese MA, Elbah M, Fnides B (2014) Machinability investigation in hard turning of AISI D3 cold work steel with ceramic tool using response surface methodology. J Adv Manuf Technol 73:1775–1788
Bartarya G, Choudhury SK (2012) State of the art in hard turning. Int J Mach Tools Manuf 53:1–14
Benga GC, Abrão AM (2003) Turning of hardened 100Cr6 bearing steel with ceramic and PCBN cutting tools. J Mater Process Technol 143–144:237–241
Bensouilah H, Aouici H, Meddour I, Yallese MA, Mabrouki T, Girardin F (2016) Performance of coated and uncoated mixed ceramic tools in hard turning process. Measurement 82:1–18
Boothroyd G, Knight WA (1989) Fundamentals of machining and machine tools. Marcel Dekker, New York
Bouacha K, Yallese MA, Mabrouki T, Rigal J-F (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 Metals Hard Mater 28:349–361
Bouzid L, Yallese MA, Chaoui K, Mabrouki T, Boulanouar L (2014) Mathematical modeling for turning on AISI 420 stainless steel using surface response methodology. Proc. IMechE Part B: J. Eng. Manuf. 1–17.
Darwish SM (2000) The impact of the tool material and the cutting parameters on surface roughness of supermet 718 nickel superalloy. J Mater Process Technol 97:10–18
Davim JP (2010) Machining of hard materials. Springer, London. doi: 10.1007/978-1-84996-450-460.
de Godoy VAA, Diniz AE (2011) Turning of interrupted and continuous hardened steel surfaces using ceramic and CBN cutting tools. J Mater Process Technol 211:1014–1025
De Oliveira AJ, Diniz AE, Ursolino DJ (2009) Hard turning in continuous and interrupted cut with PCBN and whisker-reinforced cutting tools. J Mater Process Technol 209:5262–5270
Dilbag SP, Venkateswara RA (2007) Surface roughness prediction model for hard turning process. J Adv Manuf Technol 32:1115–1124
Dureja JS, Gupat VK, Sharma VS, Dogra M (2009) Design optimization of cutting conditions and analysis of their effect on tool wear and surface roughness during hard turning of AISI-H11 steel with a coated-mixed ceramic tool. J Eng Mnuf 223:1441–1450
El Baradie MA (1991) Computer aided analysis of a surface roughness model for turning. J Mater Process Technolo 26:207–216
Elbah M, Yallese MA, Aouici H, Mabrouki T, Rigal J (2013) Comparative assessment of wiper and conventional ceramic tools on surface roughness in hard turning AISI 4140 steel. Measurement 46:3041–3056
Fnides B, Aouici H, Yallese MA (2008) Cutting forces and surface roughness in hard turning of hot work steel X38CrMoV5-1 using mixed ceramic. MECHANIKA 2(70):73–78
Fnides B, Boutabba S, Fnides M, Aouici H, Yallese MA (2013) Cutting tools flank wear and productivity investigation in straight turning of X38CrMoV5-1 (50 HRC). J App Eng Technol 3(1):1–10
Grzesik W (2009) Wear development on wiper Al2O3–TiC mixed ceramic tools in hard machining of high strength steel. Wear 266:1021–1028
Grzesik W, Wanat T (2005) Comparative assessment of surface roughness produced by hard machining with mixed ceramic tools including 2D and 3D analysis. J Mater Process Technol 169:364–371
Huang Y, Dawson TG (2005) Tool crater wear depth modeling in CBN hard turning. Wear 258(9):1455–1461
Jenn-Tsong H, Nun-Ming L, Ko-Ta C (2008) Investigating the machinability evaluation of Hadfield steel in the hard turning with Al2O3/TiC mixed ceramic tool based on the response surface methodology. J Mater Process Technol 208:532–541
Lima JG, Ávila RF, Abraõ AM, Faustino M, Davim JP (2005) Hard turning: AISI 4340 high strength low alloy steel and AISI D2 cold work tool steel. J Mater Process Technol 169:388–395
Meddour I, Yallese MA, Khattabi R, Elbah M, Boulanouar L (2015) Investigation and modeling of cutting forces and surface roughness when hard turning of AISI 52100 steel with mixed ceramic tool: cutting condition optimization. Int J Adv Manuf Technol. doi: 10.1007/s00170-014-6559-z.
Paiva AP, Campos PH, Ferreira JR, Lopes LGD, Paiva EJ, Balestrassi PP (2012) A multivariate robust parameter design approach for optimization of AISI 52100 hardened steel turning with wiper mixed ceramic tool. Int J Refract Metals Hard Mater 30:152–163
Pavel R, Marinescu I, Deis M, Pillar J (2005) Effect of tool wear on surface finish for a case of continuous and interrupted hard turning. J Mater Process Technol 170:341–349
Poulachon G, Bandyopadhyay BP, Jawahir IS, Pheulpin S, Seguin E (2003) The influence of the microstructure of hardened tool steel workpiece on the wear of PCBN cutting tools. Int J Machine Tools Manuf 43:139–144
Remadna M, Rigal J-F (2006) Evolution during time of tool wear and cutting forces in the case of hard turning with CBN inserts. J Mater Process Technol 178(1–3):67–75
Shaw MC (1984) Metal cutting principles. Oxford University Press, Oxford
Suresh PVS, Rao PV, Deshmukh SG (2002) A genetic algorithmic approach for optimization of the surface roughness prediction model. Int J Mach Tools Manuf 42:675–680
Yallese MA, Boulanouar L, Chaoui K (2004) Usinage de l’acier 100Cr6 trempé par un outil en nitrure de bore cubique. Mécanique Industries 5:355–368
Yallese MA, Rigal J-F, Chaoui K, Boulanouar L (2005) The effects of cutting conditions on mixed ceramic and cubic boron nitride tool wear and on surface roughness during machining of X200Cr12 steel (60 HRC). J Eng Manuf 219(B):35–55
Yallese MA, Chaoui K, Zeghib N, Boulanouar L, Rigal J-F (2009) Hard machining of hardened bearing steel using cubic boron nitride tool. J Mater Process Technol 209(2009):1092–1104
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Khellaf, A., Aouici, H., Smaiah, S. et al. Comparative assessment of two ceramic cutting tools on surface roughness in hard turning of AISI H11 steel: including 2D and 3D surface topography. Int J Adv Manuf Technol 89, 333–354 (2017). https://doi.org/10.1007/s00170-016-9077-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9077-3