Comparison of Ceramic and Coated Carbide Inserts Performance in Finish Turning of Hardened AISI 420 Stainless Steel

Öz

Martensitic stainless steels have a high carbon amount that can be heat treated to increase their hardness. There are widely used in cutlery, needle valves, shear blades, dental and surgical equipment. In this study finish hard turning was performed on the AISI 420 stainless steel using ceramic and coated carbide inserts under dry cutting conditions. Depth of cut, feed rate, and cutting speed were selected as machining parameters, while surface roughness was chosen as machinability criterion. Taguchi L9 orthogonal array was selected for the design of the experiment to decrease the number of trials for reducing time and cost of manufacturing. The response surface methodology was utilized for determining a relationship among process parameters and output parameter. The analysis of variance results indicates that feed rate is the utmost factor on the surface roughness for both ceramic and carbide inserts with 86.56% and 80.57% contribution, respectively. The developed mathematical models for ceramic and coated carbide inserts are capable to predict surface roughness with 97.07% and 96.13% accuracy, respectively. Based on the desirability function and response optimizer of the RSM, 0.2 mm depth of cut, 250 m/min cutting speed, and 0.05 mm/rev feed rate were selected as optimum machining factors. Finally, the mean surface roughness for ceramic and coated carbide inserts calculated as 0.57 µm and 0.71 µm, respectively. Therefore, the ceramic insert exhibited better performance compared to the coated carbide insert.

Anahtar Kelimeler

• Surface roughness
• AISI 420 stainless steel
• ceramic insert
• coated carbide insert
• RSM

Kaynakça

1. [1] El-Tamimi, A., Soliman, M., El-Hossainy, T., and Muzher, J., "Developed models for understanding and predicting the machinability of a hardened martensitic stainless steel". Materials and Manufacturing Processes. 25(8): 758-768, (2010).
2. [2] Bartarya, G. and Choudhury, S., "State of the art in hard turning". International Journal of Machine Tools and Manufacture. 53(1): 1-14, (2012).
3. [3] Singh, D. and Rao, P.V., "A surface roughness prediction model for hard turning process". The International Journal of Advanced Manufacturing Technology. 32(11-12): 1115-1124, (2007).
4. [4] ÖZDEMİR, M., Kaya, M.T., and Akyildiz, H.K., "Analysis of surface roughness and cutting forces in hard turning of 42CrMo4 steel using Taguchi and RSM method". Mechanics. 26(3): 231-241, (2020).
5. [5] Byrne, G., Dornfeld, D., and Denkena, B., "Advancing cutting technology". CIRP Annals. 52(2): 483-507, (2003).
6. [6] Zhao, X., Wei, Q., Gao, N., Zheng, E., Shi, Y., and Yang, S., "Rapid fabrication of TiN/AISI 420 stainless steel composite by selective laser melting additive manufacturing". Journal of Materials Processing Technology. 270: 8-19, (2019).
7. [7] Barlow, L.D. and Du Toit, M., "Effect of austenitizing heat treatment on the microstructure and hardness of martensitic stainless steel AISI 420". Journal of Materials Engineering and Performance. 21(7): 1327-1336, (2012).
8. [8] Noordin, M., Kurniawan, D., and Sharif, S., "Hard turning of stainless steel using wiper coated carbide tool". International Journal of Precision Technology. 1(1): 75-84, (2007).

9. [9] Kurniawan, D., Yusof, N.M., and Sharif, S., "Hard machining of stainless steel using wiper coated carbide: tool life and surface integrity". Materials and Manufacturing Processes. 25(6): 370-377, (2010).
10. [10] Makadia, A.J. and Nanavati, J., "Optimisation of machining parameters for turning operations based on response surface methodology". Measurement. 46(4): 1521-1529, (2013).
11. [11] Bouzid, L., Yallese, M.A., Belhadi, S., Mabrouki, T., and Boulanouar, L., "RMS-based optimisation of surface roughness when turning AISI 420 stainless steel". International Journal of Materials and Product Technology. 49(4): 224-251, (2014).
12. [12] Şahinoğlu, A. and Rafighi, M., "Optimization of cutting parameters with respect to roughness for machining of hardened AISI 1040 steel". Materials Testing. 62(1): 85-95, (2020).
13. [13] Şahinoğlu, A. and Rafighi, M., "Investigation of vibration, sound intensity, machine current and surface roughness values of AISI 4140 during machining on the lathe". Arabian Journal for Science and Engineering. 45(2): 765-778, (2020).
14. [14] Tanabi, H. and Rafighi, M., "Turning machinability of alloyed ductile iron compared to forged EN 1.7131 steel". Materials Testing. 62(12): 1259-1264, (2020).
15. [15] Bouzid, L., Yallese, M.A., Chaoui, K., Mabrouki, T., and Boulanouar, L., "Mathematical modeling for turning on AISI 420 stainless steel using surface response methodology". Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 229(1): 45-61, (2015).
16. [16] Zerti, A., Yallese, M.A., Meddour, I., Belhadi, S., Haddad, A., and Mabrouki, T., "Modeling and multi-objective optimization for minimizing surface roughness, cutting force, and power, and maximizing productivity for tempered stainless steel AISI 420 in turning operations". The International Journal of Advanced Manufacturing Technology. 102(1): 135-157, (2019).
17. [17] Zerti, A., Yallese, M.A., Zerti, O., Nouioua, M., and Khettabi, R., "Prediction of machining performance using RSM and ANN models in hard turning of martensitic stainless steel AISI 420". Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 233(13): 4439-4462, (2019).
18. [18] Palanisamy, D., Devaraju, A., Arulkirubakaran, D., and Manikandan, N., "Experimental investigation on surface integrity during machining of AISI 420 steel with tungsten carbide insert". Materials Today: Proceedings. 22: 992-997, (2020).