Title: Surface roughness analysis of hardened steel using TiN coated ceramic inserts

Authors: Sudhansu Ranjan Das; Amaresh Kumar; Debabrata Dhupal

Addresses: Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur, 831014, Jharkhand, India ' Department of Manufacturing Engineering, National Institute of Technology, Jamshedpur, 831014, Jharkhand, India ' Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, 768018, Odisha, India

Abstract: The present investigation is to explore the consequences of cutting parameters (v, f, d) on surface roughness (Ra) by employing combined techniques such as orthogonal array and analysis of variance in turning of hardened AISI 4140 steel with PVD-TiN coated mixed Al₂O₃+TiCN ceramic inserts under dry environment. The results show that feed is the principal cutting parameter influencing Ra, followed by cutting speed. The machined surface characterisation has been investigated in this study, along with optimisation and development of mathematical model for Ra. Additionally, the effect of tool wear on Ra has been studied. The experimental data were further analysed to predict the optimal range of Ra. Finally, based on response surface methodology (RSM) a mathematical model is developed for Ra with 95% confidence level. The effectiveness, adequacy and statistical significance of the developed model has been checked using ANOVA analysis, Anderson-Darling test and normal probability plot.

Keywords: hard turning; AISI 4140 steel; TiN coatings; titanium nitride; ceramic inserts; surface roughness; analysis of variance; ANOVA; response surface methodology; RSM; orthogonal arrays; surface quality; feed; cutting speed; mathematical modelling; tool wear.

DOI: 10.1504/IJMMM.2015.069217

International Journal of Machining and Machinability of Materials, 2015 Vol.17 No.1, pp.22 - 38

Received: 26 Jun 2014
Accepted: 14 Nov 2014
Published online: 05 May 2015 *

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