In this research, the exponential and quadratic polynomial empirical models for three-component cutting forces by employing five factors, such as the cutting speed, depth of cut, feed, workpiece hardness, and nose radius, were developed by utilizing the orthogonal regression methodology (ORM) and response surface methodology (RSM). On the other hand, an attempt has been made to experimentally investigate the effects of those factors on three-component cutting forces in finish dry hard turning (FDHT) of tool steel AISI D2 with the PCBN tool. In this investigation, based on five-factor three-level orthogonal experiments, three-component cutting forces were measured, and then, analysis of variance (ANOVA) was performed to estimate the significance of developed models and analyze the main and interaction effects of the factors. The experimental results indicated that the RSM quadratic polynomial empirical model (RSMQPEM) is much more accurate and credible than the ORM exponential empirical model (ORMEM) in predicting the three-component cutting forces. It was also found that the cutting speed and feed are the two dominant factors affecting the main cutting forces F
 Z; the feed is the one dominant factor affecting radial cutting force F
 Y and the feed cutting force F
 X. Additionally, the optimum cutting parameters for the hardened materials with 51, 55, 60, and 64 HRC was found.

Empirical models for cutting forces in finish dry hard turning of hardened tool steel at different hardness levels

The effect of cutting speed, feed rate and depth of cut on cutting force, surface roughness and tool wear are investigated in this study. For this purpose 316SS is machined with dry cutting conditions by all Gear lathe with commercial grade of tungsten carbide (DCMT 11T304 TN200) inserts having a nose radius of 0.6mm. Metal removing process is carried out for three different cutting speeds, feed rates and depth of cuts. The effect of cutting speeds, feed rates, and depth of cut on surface roughness, cutting forces and tool wear of the tungsten carbide (WC) insets was experimented and analyzed by using analysis of variance (ANOVA) technique. Optimal cutting parameters for each performance measure were obtained; also the relationship between the parameters and the performance measures were determined using multiple linear regressions.

Behavior of Machining Parameters in Hard Turning of 316 Stainless Steel

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Behavior of Machining Parameters in Hard Turning of 316 Stainless Steel