Skip to main content
SpringerLink
Log in

Force prediction model of Zirconia Toughened Alumina (ZTA) inserts in hard turning of AISI 4340 steel using response surface methodology

  • Published:
International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed and depth of cut) on machining forces (feed force, thrust force and cutting force) in finish hard turning of AISI 4340 steel using developed Zirconia Toughened Alumina (ZTA) insert prepared by powder metallurgy process route. The machining experiments were performed based on standard Response Surface Methodology (RSM) called Central Composite Design (CCD). The mathematical model of each forces have been developed using second order regression analysis. The adequacy of the models and influence of each operating factors have been carried out based on Analysis of Variance (ANOVA) techniques. It can be concluded from the present study that cutting speed and depth of cut have predominant effect on feed force whereas feed and depth of cut are the two most influencing factors for thrust force determination. But, in case of cutting force modeling, all the three parameters (feed rate, depth of cut and cutting speed) have significant effect. Key parameters and their effects on forces have also been presented in graphical contours which may help for choosing operating parameter preciously. Optimized model indicates 76.51% desirability level for economy in conventional machining process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Montgomery, D. C., “Design and Analysis of experiments, 5th Eds.,” New York, Wiley, 2007.

    Google Scholar 

  2. Lalwani, D. I., Mehta, N. K., and Jain, P. K., “Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel,” Journal of Materials Processing Technology, Vol. 206, No. 1–3, pp. 167–179, 2008.

    Article  Google Scholar 

  3. Horng, J.-T., Liu, N.-M., and Chiang, K.-T., “Investigating the machinability evaluation of Hadfield steel in the hard turning with Al2O3/TiC mixed ceramic tool based on the response surface methodology,” Journal of Materials Processing Technology, Vol. 208, No. 1–3, pp. 532–541, 2008.

    Article  Google Scholar 

  4. Ramanujam, R., Muthukrishnan, N., and Raju, R., “Optimization of cutting parameters for turning Al-SiC(10p) MMC using ANOVA and grey relational analysis,” Int. J. Precis. Eng. Manuf., Vol. 12, No. 4, pp. 651–656, 2011.

    Article  Google Scholar 

  5. Chun, S. H. and Ko, T. J., “Study on the response surface model of machining error in internal lathe boring,” Int. J. Precis. Eng. Manuf., Vol. 12, No. 2, pp. 177–182, 2011.

    Article  Google Scholar 

  6. Raju, K. M. V. K., Janardhana, R. G., Kumar, N. P., and Rao, V. P. D., “Optimization of cutting conditions for surface roughness in CNC end milling,” Int. J. Precis. Eng. Manuf., Vol. 12, No. 3, pp. 383–391, 2011.

    Article  Google Scholar 

  7. Özel, T., Karpat, Y., Figueira, L., and Davim, J. P., “Modelling of surface finish and tool flank wear in turning of AISI D2 steel with ceramic wiper inserts,” Journal of Materials Processing Technology, Vol. 189, No. 1–3, pp. 192–198, 2007.

    Article  Google Scholar 

  8. Dureja, J. S., Gupta, V. K., Sharma, V. S., and Dogra, M., “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,” Journal of Engineering Manufacture, Vol. 223, No. 11, pp. 1441–1453, 2009.

    Article  Google Scholar 

  9. Thangavel, P., Selladurai, V., and Shanmugam, R., “Application of response surface methodology for predicting flank wear in turning operation,” Journal of Engineering Manufacture, Vol. 220, No. 6, pp. 997–1003, 2006.

    Article  Google Scholar 

  10. Huang, Y. and Liang, S. Y., “Effect of Cutting Conditions on Tool Performance in CBN Hard Turning,” Journal of Manufacturing Processes, Vol. 7, No. 1, pp. 10–16, 2005.

    Article  Google Scholar 

  11. Amaitik, S. M., Tasgin, T. T., and Kilic, S. E., “Tool life modeling of carbide and ceramic cutting tools using multi linear regression analysis,” Journal of Engineering Manufacture, Vol. 220, No. 2, pp. 129–136, 2006.

    Article  Google Scholar 

  12. Sahin, Y. and Motorcu, A. R., “Surface roughness model for machining mild steel with coated carbide tool,” Materials & Design, Vol. 26, No. 4, pp. 321–326, 2005.

    Article  Google Scholar 

  13. Sahin, Y. and Motorcu, A. R., “Surface roughness model in machining hardened steel with cubic boron nitride cutting tool,” International Journal of Refractory Metals and Hard Materials, Vol. 26, No. 2, pp. 84–90, 2008.

    Article  Google Scholar 

  14. Noordin, M. Y., Venkatesh, V. C., Sharif, S., Elting, S., and Abdullah, A., “Application of response surface methodology in describing the performance of coated carbide tools when turning AISI 1045 steel,” Journal of Materials Processing Technology, Vol. 145, No. 1, pp. 46–58, 2004.

    Article  Google Scholar 

  15. Gaitonde, V. N., Karnik, S. R., Figueira, L., and Paulo Davim, J., “Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts,” International Journal of Refractory Metals and Hard Materials, Vol. 27, No. 4, pp. 754–763, 2009.

    Article  Google Scholar 

  16. Gaitonde, V. N., Karnik, S. R., Figueira, L., and Paulo Davim, J., “Analysis of Machinability During Hard Turning of Cold Work Tool Steel (Type: AISI D2),” Journal of Materials & Manufacturing Processes, Vol. 24, No. 12, pp. 1373–1382, 2009.

    Article  Google Scholar 

  17. Paulo Davim, J. and Figueira, L., “Comparative evaluation of conventional and wiper ceramic tools on cutting forces, surface roughness, and tool wear in hard turning AISI D2 steel,” Journal of Engineering Manufacture, Vol. 221, No. 4, pp. 625–633, 2007.

    Article  Google Scholar 

  18. Paulo Davim, J. and Figueira, L., “Machinability evaluation in hard turning of cold work tool steel (D2) with ceramic tools using statistical techniques,” Materials & Design, Vol. 28, No. 4, pp. 1186–1191, 2007.

    Article  Google Scholar 

  19. De Lima, J. G., De vila, R. F., and Abrão, A. M., “Turning of hardened AISI 4340 steel using coated carbide inserts,” Journal of Engineering Manufacture, Vol. 221, No. 8, pp. 1359–1366, 2007.

    Article  Google Scholar 

  20. Sikdar, S. K. and Chen, M., “Relationship between tool flank wear area and component forces in single point turning,” Journal of Materials Processing Technology, Vol. 128, No. 1–3, pp. 210–215, 2002.

    Article  Google Scholar 

  21. Dogra, M., Sharma, V., Sachdeva, A., Suri, N., and Dureja, J., “Performance evaluation of CBN, coated carbide, cryogenically treated uncoated/coated carbide inserts in finish-turning of hardened steel,” The International Journal of Advanced Manufacturing Technology, Vol. 57, No. 5–8, pp. 541–553, 2011.

    Article  Google Scholar 

  22. Senthil Kumar, A., Raja Durai, A., and Sornakumar, T., “Development of alumina-ceria ceramic composite cutting tool,” International Journal of Refractory Metals and Hard Materials, Vol. 22, No. 1, pp. 17–20, 2004.

    Article  Google Scholar 

  23. Senthil Kumar, A., Raja Durai, A., and Sornakumar, T., “Machinability of hardened steel using alumina based ceramic cutting tools,” International Journal of Refractory Metals and Hard Materials, Vol. 21, No. 3–4, pp. 109–117, 2003.

    Article  Google Scholar 

  24. Mandal, N., Doloi, B., and Mondal, B., “Development of flank wear prediction model of Zirconia Toughened Alumina (ZTA) cutting tool using response surface methodology,” International Journal of Refractory Metals and Hard Materials, Vol. 29, No. 2, pp. 273–280, 2011.

    Article  Google Scholar 

  25. Mondal, B., “Zirconia toughened alumina for wear resistant engineering and machinability of steel application,” Advances in Applied Ceramics, Vol. 104, No. 5, pp. 256–260, 2005.

    Article  Google Scholar 

  26. Senthil Kumar, A., Raja Durai, A., and Sornakumar, T., “Development of yttria and ceria toughened alumina composite for cutting tool application,” International Journal of Refractory Metals and Hard Materials, Vol. 25, No. 3, pp. 214–219, 2007.

    Article  Google Scholar 

  27. Dutta, A. K., Chattopadhyaya, A. B., and Ray, K. K., “Progressive flank wear and machining performance of silver toughened alumina cutting tool inserts,” Wear, Vol. 261, No. 7–8, pp. 885–895, 2006.

    Article  Google Scholar 

  28. Mondal, B., “Development and Performance of aluminazirconia cutting tool inserts,” Ph.D. Thesis, IIT Kharagpur, India, 1989.

    Google Scholar 

  29. Claussen, N., “Stress-induced transformation of tetragonal ZrO2 particles in ceramic matrices,” Journal of American Ceramic Society, Vol. 61, No. 1–2, pp. 85–86, 1978.

    Article  Google Scholar 

  30. Lange, F. F., “Transformation toughening, Part I–Part 5,” Journal of Materials Science, Vol. 17, No. 1, pp. 225–263, 1982.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Centre for Advanced Materials Processing, CSIR-Central Mechanical Engineering Research Institute, Durgapur, India, 713209

    Nilrudra Mandal & Biswanath Mondal

  2. Production Engineering Department, Jadavpur University, Jadavpur, Kolkata, India, 700032

    Biswanath Doloi

Authors
  1. Nilrudra Mandal
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Biswanath Doloi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Biswanath Mondal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Nilrudra Mandal.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Mandal, N., Doloi, B. & Mondal, B. Force prediction model of Zirconia Toughened Alumina (ZTA) inserts in hard turning of AISI 4340 steel using response surface methodology. Int. J. Precis. Eng. Manuf. 13, 1589–1599 (2012). https://doi.org/10.1007/s12541-012-0209-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12541-012-0209-x

Keywords

Search

Navigation