Temperature and Cutting Force Analysis in Turning of Steel AISI 4140 using Advanced Ceramics tools

Abstract

Past two decades, the usage of ceramic tools has increased especially in milling and turning process. These advanced ceramic tools have good characteristics that are capable in maintaining high hardness in temperatures and also wears much slower when compared to carbide tools. With limited data available on the tool itself, research is to be done on these advance ceramic tools. The main purpose of this research project is to determine the cutting parameters affecting the cutting temperature and cutting force. The cutting parameters such as cutting speed, depth of cut and feed rate are considered as variables. Silicon Nitride is chosen as the tool and Steel AISI4140 is chosen as the work piece. Analysis is conducted through Box-Behnken method with 3 levels, 3 factors and 2 responses. The regression model for cutting temperature and cutting force responses are identified. Analysis of Variance (ANOVA) is done to determine the effect of the cutting parameters and their contribution towards the cutting temperature and cutting force response. It was found that feed rate has the most influence on cutting temperature and force. The optimal cutting parameters that produce the lowest cutting temperature and lowest cutting force are obtained at values of 615 m/min cutting speed, 0.3 mm/rev feed rate, and 0.5 mm depth of cut.