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Machinability Investigations on High Chrome White Cast Iron Using Multi Coated Hard Carbide Tools

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Abstract

This study investigated the performance of multilayer hard coated carbide tool and multi-response optimization of the turning process for an optimal parametric combination to yield the minimum cutting forces and machining power with a maximum material removal rate (MRR) using Taguchi and artificial neural network (ANN) methods. In recent times, high chrome white cast iron finds increasing applications in aerospace, mining, mineral process industries. Its machinability using carbide insert (TiC/TiCN/Al2O3) cutting tool has been studied. The influences of cutting parameters on the cutting forces, MRR and machining power of the process have been analyzed using analysis of variance and the results are correlated using ANN. Linear regression method was used to establish the relation between the cutting parameters and the process responses. The confirmation test reveals that, the accuracy of prediction of ANN is better than that of the regression analysis. In view of the good performance of the carbide tools (at optimum conditions), it can replace the cosly CBN, with improved economic benefits.

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Abbreviations

AISI:

American Iron and Steel Institute

ANOVA:

Analysis of variance

BHN:

Brinnell hardness number

CBN:

Cubic boron nitride cutting tool

CVD:

Chemical vapor deposition process

DF:

Degrees-of-freedom

d :

Depth of cut (mm)

f :

Feed rate (mm/rev)

F:

Statistical characteristics

F c :

Main cutting force (N)

F f :

Feed force (N)

F t :

Thrust force (N)

HCWCI:

High chrome white cast iron

HRC:

Hardness value by Rockwell

MRR:

Material removal rate (mm3/min)

MS:

Mean of squares

MSE:

Mean square error

P m :

Machining power (KW)

P:

Contribution (%)

RSM:

Response surface method

Ra :

Average surface roughness (μm)

R2adj:

Adjusted coefficient of multiple correlation

S :

Cutting speed (m/min)

SS:

Sum of squares

S/N:

Signal-to-noise ratio

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Acknowledgments

The authors wish to thank Mr. Damodar Baliga, Managing Director of M/s Vasavi Foundry Pvt. Ltd., Shimoga, Karnataka, India, for his invaluable assistance to carry out this research work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore, 577025, India

    A. M. Ravi & S. M. Murigendrappa

  2. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Kharagpur, Kharagpur, 721302, India

    P. G. Mukunda

Authors
  1. A. M. Ravi
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  2. S. M. Murigendrappa
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  3. P. G. Mukunda
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Corresponding author

Correspondence to S. M. Murigendrappa.

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Ravi, A.M., Murigendrappa, S.M. & Mukunda, P.G. Machinability Investigations on High Chrome White Cast Iron Using Multi Coated Hard Carbide Tools. Trans Indian Inst Met 67, 485–502 (2014). https://doi.org/10.1007/s12666-013-0369-0

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