Experimental analysis and effect of interface temperature and chip morphology on surface roughness & flank wear in hard turning of AISI 52100

Abstract

In this research work, hard turning of AISI 52100 (chrome steel) having hardness of 57 HRC is considered
for analysis of machined surface roughness and tool flank wear using CBN cutting tool insert. This chrome steel bears
having high hardness, wear resistance, surface finishing and dimensional precision; it is widely used to manufacture
mechanical components, notably in balls and roller bearing. The temperature developed during machining is critical for
analysis since it effects wear of the cutting tool and increases the surface roughness of the machined surface. The
interface temperature, surface roughness, flank wear and chip morphology generated during machining will depend on
the machining parameters chosen for this material. Experiments are designed based on Taguchi's Design of Experiment,
for three input parameters each has three levels based on an L9 Orthogonal array. The output responses are analyzed
based on Signal-to-Noise ratio and statistical tool like ANOVA and regression. The effect of interface temperature and
chip morphology on surface roughness and flank wear is analyzed and the optimum cutting conditions are evaluated for
minimizing surface roughness of work piece and tool flank wear to a considerable amount. The experimental results
indicated that rise in interface temperature increases the surface roughness and tool flank wear. At optimum condition
surface roughness value decreases when shape of chip changes from continuous to discontinues type. Results also shows
when flank wear increases, shape of chip changes from continuous spring saw tooth wavy type to continuous spring one
side flat one side saw tooth type chip.