Kondekar, et al, International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Review Article
OPTIMIZATION OF TURNING PROCESS PARAMETERS
THROUGH DOE FOR `SURFACE FINISH AND `TOOL WEAR
1
Arvind Kondekar, 2S.S.Sarnobat, 3Swapnil S. Kulkarni

Address for Correspondence

1
ME- Mechanical- Production Engineering - pursuing, 2Asst Professor, Department of Production Engineering,
D.Y.Patil College of Engineering,Akurdi, Pune, 3Director-Able Technologies India Pvt. Ltd., Pune
INTRODUCTION:
Turning is the removal of metal from the outer
diameter of a rotating cylindrical work piece. Turning
is used to reduce the diameter of the work piece,
usually to a specified dimension, and to produce a
smooth finish on the metal. Often the work piece will
be turned so that adjacent sections have different
diameters. Turning is the machining operation that
produces cylindrical parts. In its basic form, it can be 4340 steel was evaluated. An attempt has been made
defined as the machining of an external surface:-
With the work piece rotating,
With a single-point cutting tool, and
With the cutting tool feeding parallel to the
axis of the work piece and at a distance that
will remove the outer surface of the work.
In this challenging world, industries around the world
constantly strive for lower cost solutions with
reduced lead time and better surface quality in order
to maintain their competitiveness. Automated and
flexible manufacturing systems are employed for that
purpose along with computerized numerical control
(CNC) machines that are capable of achieving high
accuracy and very low processing time. In the CNC
machining, determining optimal cutting conditions or
parameters under the given machining situation is
difficult in practice. Conventional way for selecting
these conditions such as cutting speed and feed rate
has been based upon data from machining handbooks
and/or on the experience and knowledge on the part
of programmer. As a result, the metal removal rate is
low because of the use of such conservative
machining parameters.
Turning is the first most common method for cutting
and especially for the finishing machined parts. In a
turning operation, it is important task to select cutting The quadratic model of RSM associated with
parameters for achieving high cutting performance.
Cutting parameters are reflected on surface
roughness, surface texture and dimensional
deviations of the product. Surface finish obtained in
manufacturing processes mainly depends on the
combination of two aspects: the ideal surface finish
provided by marks that manufacturing process
produces on the surface and the actual surface finish
which is generated taking into account irregularities
and deficiencies that may appear in the process,
changing manufacturing initial conditions. The
purpose of this project work is to investigate the
surface roughness on engineering components by
turning process. To achieve the result of surface
roughness, the material used for the investigation is
Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/14-16
AISI D2 (three levels of hardness). Thus, the surface
roughness is planned to be measured and observed in
the experiment.
LITERATURE REVIEW
R. Suresh[1], In the present study, performance of
multilayer hard coatings (TiC/TiCN/Al2O3) on
cemented carbide substrate using chemical vapor
deposition (CVD) for machining of hardened AISI
to analyze the effects of process parameters on
machinability aspects using Taguchi technique.
Response surface plots are generated for the study of
interaction effects of cutting conditions on
machinability factors. The correlations were
established by multiple linear regression models. The
linear regression models were validated using
confirmation tests. The analysis of the result revealed
that, the optimal combination of low feed rate and
low depth of cut with high cutting speed is beneficial
for reducing machining force. Higher values of feed
rates are necessary to minimize the specific cutting
force. The machining power and cutting tool wear
increases almost linearly with increase in cutting
speed and feed rate. The combination of low feed rate
and high cutting speed is necessary for minimizing
the surface roughness. Abrasion was the principle
wear mechanism observed at all the cutting
conditions.
Zahia Hessainia[2], This research work concerns the
elaboration of a surface roughness model in the case
of hard turning by exploiting the response surface
methodology (RSM). The main input parameters of
this model are the cutting parameters such as cutting
speed, feed rate, depth of cut and tool vibration in
radial and in main cutting force directions. The
machined material tested is the 42CrMo4 hardened
steel by Al2O3/TiC mixed ceramic cutting tool under
different conditions. The model is able to predict
surface roughness of Ra and Rt using an
experimental data when machining steels. The
combined effects of cutting parameters and tool
vibration on surface roughness were investigated
while employing the analysis of variance (ANOVA).
response optimization technique and composite
desirability was used to find optimum values of
cutting parameters and tool vibration with respect to
announced objectives which are the prediction of
surface roughness.
Mustafa Gunay[3], This paper focused on optimizing
the cutting conditions for the average surface
roughness (Ra) obtained in machining of high-alloy
white cast iron (Ni-Hard) at two different hardness
levels (50 HRC and 62 HRC). Machining
experiments were performed at the CNC lathe using
ceramic and cubic boron nitride (CBN) cutting tools
on Ni-Hard materials. Cutting speed, feed rate and
depth of cut were chosen as the cutting parameters.
Taguchi L18 orthogonal array was used to design of
 Kondekar, et al, International Journal of Advanced Engineering Research and Studies
experiment. Optimal cutting conditions was
determined using the signal-to-noise (S/N) ratio
which was calculated for Ra according to the the-
smaller-the-better approach. The effects of the
cutting parameters and tool materials on surface
roughness were evaluated by the analysis of variance.
The statistical analysis indicated that the parameters
that have the biggest effect on Ra for Ni-Hard
materials with 50 HRC and 62 HRC are the cutting
speed and feed rate, respectively. Additionally, the
optimum cutting conditions for the materials with 50
HRC and 62 HRC was found at different levels.
Halil C- als-kan[4], The influence of nano layer
AlTiN/TiN and multi layer nano composite TiAlSiN
/TiSiN /TiAlN hard coatings on the wear behavior
and cutting performance of carbide cutting tools was
investigated in face milling of hardened AISIO2 cold
work tool steel (58HRC) at dry conditions.
Characterization of the coatings was performed using
nano indentation, scratch test, reciprocating multi-
pass wear test. The chips forming during cutting
process were also analyzed. Results showed that
abrasive and oxidation wear are dominant tool
failures. Then nano layer AlTiN/TiN coating gives
the best adhesion to the substrate, the best wear
resistance in machining and thus provides the longest
lifetime with carbide inserts.
J. Kenda[5], The abrasive flow machining (AFM) is a
recent manufacturing technique that uses the flow of
a pressurized abrasive media for removing work
piece material. In comparison with hand polishing,
AFM is very efficient process, suitable for finishing
of complex surfaces. In this paper, the influence of
the process parameters on surface integrity, i.e.
surface roughness and induced residual stresses, is
investigated. The electrical discharge pre-machined
hardened tool steel AISI D2 samples have been used
to be processed with AFM. Results of the work show
that AFM is capable to remove EDM damaged
surface and significantly improve surface roughness.
Moreover, it is capable of inducing high compressive
residual stresses to the machined surface, in a very
thin sub layer of ~10 m, and so proves that AFM
offers an alternative finishing process, beneficial
from the surface integrity and productivity point of
view.
PROPOSED WORK:
The objective of this research is to study the effect of
cutting speed, feed, depth of cut, machining time on
surface roughness. Taylor showed that an optimum or
economic cutting speed exists which could maximize
material removal rate. Considerable efforts are still in
progress on the use of hand book based conservative
cutting conditions and cutting tool selection at the
process planning level. The need for selecting and
implementing optimal machining conditions and
most suitable cutting tool has been felt over the last
few decades. Despite Taylors early work on
establishing optimum cutting speeds in machining,
progress has been slow since all the process
parameters need to be optimized.
SCOPE:
The study was aimed on the spindle speed, feed rate,
and depth of cut on the surface roughness of the work
piece. The variants for AISI D2 with three variants of
hardness as 40~45, 45~50, 50~55 HRC to be used as
the work piece material and the cutting tool (insert) to
be CBN(coated) and Cermet. For this test, no
Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/14-16
E-ISSN22498974
variation in the coolant is suggested. As such, this
factor remains constant throughout the test. The
surface roughness would be tested by using surface
roughness tester.
PROBLEM STATEMENT:
Optimization of turning parameters is usually a
difficult work where the following aspects are require
such as like knowledge of machining and the
specification of machine tool capabilities.
The level of parameters is the main point because it
will affect the surface of the work piece, it also to
avoid from scratch marks or inaccuracies in the cut.
In a turning operation, it is important task to select a
good combination of parameters level for achieving
high cutting performance.
METHODOLOGY:
Design of Experimental set-up: Experimental set-up
is designed for evaluation and determination of
optimum cutting parameters for workpiece material
AISI D2 using a typical CNC Turning Centre like
Ace as shown in Fig.1 below.
Experiment will be carried out by turning a test bar of
D2 on a CNC turning centre at different cutting and
depth of cut. For this experiment the whole work will
be carried out by compact CNC turning centre
following typical specifications.
Model:-Ace (CNC Turning Centre)
Capacity:-Maximum turning diameter 370 mm.
Cross travel: -X-205mm, Z-670 mm.
For this experiment the work piece and insert
material used during turning on CNC are given
below.
Work piece material used: AISIS D2
Tool material:- Cubic Boron Nitride (CBN)-
coated or Cermet (Ceramic).
Environment: - Wet (coolant ON)
Instrumentation: Suitable Micrometer Screw
Gauge, Digital Vernier Caliper, Surface roughness
tester
Measurements: The surface roughness (Ra) values
of all experiments will be measured by using the
surface roughness tester.
Expected outcome of work: The present work will
be helpful to predict the influence of cutting speed,
feed, depth of cut and various insert materials in dry
or wet condition on surface roughness (Ra) using
Design of experiments (DOE) and statistical
techniques for D2 Metal matrix composite on
 Kondekar, et al, International Journal of Advanced Engineering Research and Studies E-ISSN22498974
specified compact CNC turning centre. Since, this is
a material in a special class i.e. MMC, not much
research have been done on the same and this would
be helpful in improving productivity at a reasonable
level of quality.
REFERENCES:
1. Some studies on hard turning of AISI 4340 steel using
multilayer coated carbide tool R. Suresh, S. Basavarajappa,
G.L. Samuel.
2. On the prediction of surface roughness in the hard
turning based on cutting parameters and tool vibrations
Zahia Hessainia , Ahmed Belbah , Mohamed Athmane
Yallese, Tarek Mabrouki, Jean-Franois Rigal a Mechanics
and Structures Research Laboratory (LMS), May 8th 1945
University, PO Box 401, Guelma 24000, Algeria
b LaMCos, CNRS, INSA-Lyon, UMR5259, Lyon University,
F69621 Lyon, France
3. Application of Taguchi method for determining
optimum surface roughness in turning of high-alloy white
cast iron
Mustafa Gunay, Emre Yucel ,a Department of Mechanical
Engineering, Faculty of Engineering, Karabk University,
78050 Karabk, Turkey Department of Mechanical Education,
Faculty of Technical Education, Dzce University, 81620
Dzce, Turkey.
4.Wear behavior and cutting performance of nano
structured hard coating son cemented carbide cutting tools
in hard milling Halil C- als-kan, CahitKurbanoglu,
PeterPanjan , Miha Cekada, DavorinKramar, a Department
ofMechanicalEngineering,BartnUniversity,74100Bartn,Turke
y b Department of Mechanical Engineering, Istanbul
Medeniyet University,34730,Slovenia.
5. Surface Integrity in Abrasive Flow Machining of
Hardened Tool Steel AISI D2
J. Kenda*, F. Pusavec, G. Kermouche, J. Kopac, a University
of Ljubljana, Faculty of Mechanical Engineering, Askerceva 6,
Ljubljana 1000, Slovenia University of Lyon, ENISE, rue Jean
Parot 58, Saint-Etienne 42023, France.

Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/14-16