Investigation of Various Machining Characteristics Of AISI 4340 Hardened Alloy Steel With Different Uncoated Cermet Inserts

Abstract

In the current experimental investigation, the comparative assessment of various responses such as machining forces, flank wear, crater wear, chip morphology and surface roughness were carried out during machining of hardened steel with different cermet inserts under dry cutting condition. Analysis of variance was performed to identify the significant factors for the responses. Regression equations were established to correlate the input variables with the responses. Lastly the input variables were optimized using Response surface methodology (RSM) to evaluate the tool life for the economic analysis. The experimental outcomes demonstrated that uncoated deep cryotreated with tempered cermet insert delivered better results in comparison to other cermet inserts. According to cost analysis, uncoated and untreated cermet was found to be the most economical among other cermet inserts at the optimum cutting condition. Surface roughness and radial force were predominantly affected by cutting speed and feed for all cermet inserts used in this experimental work i.e. ( UCUTUncoated & untreated, UCSCT - Uncoated & shallow cryotreated, UCSCTT - Uncoated & shallow cryotreated with tempered, UCDCT - Uncoated & deep cryotreated and UCDCTT - Uncoated & deep cryotreated with tempered.). Cutting speed was the most dominating factor for flank wear, feed force and cutting force in case of UCDCTT, UCDCT and UCSCT cermet insert, whereas depth of cut significantly influenced both flank wear and cutting force for UCSCTT cermet insert.