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Simulation of the influence of cutting speed and feed rate on tool life in hard turning of AISI 4140 steel

Phacharadit Paengchit
Phacharadit Paengchit
 und 
Charnnarong Saikaew
Charnnarong Saikaew
   | 26. Okt. 2023
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Online veröffentlicht: 26. Okt. 2023
Seitenbereich: 311 - 324
Eingereicht: 20. Jan. 2023
Akzeptiert: 22. Aug. 2023
DOI: https://doi.org/10.2478/msp-2023-0021
Schlüsselwörter
© 2023 Phacharadit Paengchit et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1.

Overview of the experimental work and the machine samples
Overview of the experimental work and the machine samples

Fig. 2.

SEM images of (a) Al2O3+TiC and (b) TiN+AlCrN worn inserts after turning for 45 min
SEM images of (a) Al2O3+TiC and (b) TiN+AlCrN worn inserts after turning for 45 min

Fig. 3.

SEM images of (a) Al2O3+TiC and (b) TiN+AlCrN failed inserts after turning for more than 75 min
SEM images of (a) Al2O3+TiC and (b) TiN+AlCrN failed inserts after turning for more than 75 min

Fig. 4.

Ra versus cutting time during turning workpiece samples using (a) Al2O3+TiC and (b) TiN+AlCrN tool inserts by varying cutting speeds
Ra versus cutting time during turning workpiece samples using (a) Al2O3+TiC and (b) TiN+AlCrN tool inserts by varying cutting speeds

Fig. 5.

Ra versus cutting time during turning workpiece samples using (a) Al2O3+TiC and (b) TiN+AlCrN tool inserts by varying feed rates
Ra versus cutting time during turning workpiece samples using (a) Al2O3+TiC and (b) TiN+AlCrN tool inserts by varying feed rates

Fig. 6.

A plot of the relationship between predicted tool life values and cutting speed while keeping the feed rate constant at 0.06 mm/rev
A plot of the relationship between predicted tool life values and cutting speed while keeping the feed rate constant at 0.06 mm/rev

Fig. 7.

A plot of the relationship between predicted tool life values and feed rate while keeping the cutting speed constant at 220 m/min
A plot of the relationship between predicted tool life values and feed rate while keeping the cutting speed constant at 220 m/min

Fig. 8.

Predicted tool life values of Al2O3+TiC by varying cutting speeds (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 220 m/min while keeping the feed rate constant at 0.06 mm/rev
Predicted tool life values of Al2O3+TiC by varying cutting speeds (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 220 m/min while keeping the feed rate constant at 0.06 mm/rev

Fig. 9.

Predicted tool life values of TiN+AlCrN by varying cutting speeds (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 220 m/min while keeping the feed rate constant at 0.06 mm/rev
Predicted tool life values of TiN+AlCrN by varying cutting speeds (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 220 m/min while keeping the feed rate constant at 0.06 mm/rev

Fig. 10.

Predicted tool life values of Al2O3+TiC by varying feed rates (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 0.06 mm/rev while keeping the cutting speed constant at 220 m/min
Predicted tool life values of Al2O3+TiC by varying feed rates (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 0.06 mm/rev while keeping the cutting speed constant at 220 m/min

Fig. 11.

Predicted tool life values of TiN+AlCrN by varying feed rates (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 0.06 mm/rev when keeping the cutting speed constant at 220 m/min
Predicted tool life values of TiN+AlCrN by varying feed rates (a) −10%, (b) −5%, (c) 5%, and (d) 10% from 0.06 mm/rev when keeping the cutting speed constant at 220 m/min

Predicted tool life values of the two tool inserts by varying cutting speeds −10%, −5%, 5%, and 10% from 220 m/min while keeping the feed rate constant at 0.06 mm/rev

% Change Al2O3+TiC TiN+AlCrN
Average S.D. Average S.D.
−10 65.92 25.37 46.65 18.33
−5 55.75 20.08 38.32 14.27
5 40.33 12.74 27.42 9.00
10 34.66 10.36 23.48 7.73

Predicted tool life values of the two tool inserts by varying feed rates −10%, −5%, 5%, and 10% from 0.06 mm/rev when keeping the cutting speed constant at 220 m/min

% Change Al2O3+TiC TiN+AlCrN
Average S.D. Average S.D.
−10 48.46 4.35 33.13 3.22
−5 46.36 3.97 31.65 2.90
5 42.79 3.28 29.02 2.41
10 41.30 3.01 27.91 2.18

Results of Ra (in μm) values of the machined samples at different cutting times

Cutting time (min) Al2O3+TiC TiN+AlCrN
Cutting speed (m/min) (Holding feed rate constant at 0.06 mm/rev) Feed rate (mm/rev) (Holding cutting speed constant at 220 m/min) Cutting speed (m/min) (Holding feed rate constant at 0.06 mm/rev) Feed rate (mm/rev) (Holding cutting speed constant at 220 m/min)
200 220 240 0.04 0.06 0.08 200 220 240 0.04 0.06 0.08
5 0.594 0.610 0.635 0.532 0.610 0.634 0.612 0.634 0.691 0.610 0.634 0.683
5 0.561 0.606 0.656 0.556 0.606 0.673 0.608 0.638 0.673 0.620 0.638 0.698
5 0.534 0.608 0.647 0.545 0.608 0.657 0.616 0.641 0.680 0.640 0.641 0.687
15 0.583 0.646 0.713 0.597 0.646 0.689 0.728 0.701 0.759 0.668 0.701 0.712
15 0.602 0.645 0.734 0.566 0.645 0.741 0.684 0.715 0.772 0.658 0.715 0.754
15 0.563 0.653 0.720 0.579 0.653 0.732 0.691 0.718 0.769 0.678 0.718 0.761
30 0.637 0.732 0.853 0.643 0.732 0.857 0.775 0.835 0.919 0.774 0.835 1.064
30 0.629 0.713 0.824 0.621 0.713 0.837 0.769 0.828 0.906 0.723 0.828 0.937
30 0.631 0.698 0.810 0.639 0.698 0.823 0.793 0.821 0.912 0.734 0.821 0.986
45 0.796 0.850 0.961 0.801 0.850 0.990 0.864 1.030 1.130 0.876 1.030 1.302
45 0.771 0.852 0.927 0.778 0.852 1.064 0.854 0.998 1.138 0.857 0.998 1.282
45 0.782 0.840 0.945 0.764 0.840 1.107 0.879 0.981 1.122 0.869 0.981 1.292
60 0.938 0.945 1.097 0.920 0.945 1.217 1.162 1.173 1.293 1.018 1.173 1.489
60 0.979 0.989 1.109 0.897 0.989 1.120 1.127 1.153 1.280 1.031 1.153 1.491
60 0.901 0.918 1.073 0.883 0.918 1.327 1.136 1.149 1.253 1.011 1.149 1.487
75 1.108 1.097 1.142 1.092 1.097 1.378 1.474 1.474 1.625 1.253 1.474 1.881
75 1.058 1.112 1.198 1.035 1.112 1.392 1.513 1.342 1.488 1.271 1.342 1.687
75 1.074 1.096 1.124 1.066 1.096 1.346 1.486 1.472 1.581 1.213 1.472 1.774
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