Title: Analysis of chip morphology in dry hard turning of AISI 52100 alloy steel using RSM

Authors: Zahid A. Khan; Suha K. Shihab; Arshad Noor Siddiquee

Addresses: Mechanical Engineering Department, Jamia Millia Islamia (A Central University), New Delhi, 110025, India ' Mechanical Engineering Department, Jamia Millia Islamia (A Central University), New Delhi, 110025, India ' Mechanical Engineering Department, Jamia Millia Islamia (A Central University), New Delhi, 110025, India

Abstract: This paper presents chip morphology analysis in hard turning of AISI 52100 alloy steel with multilayer hard surface coating (TiN/TiCN/Al₂O₃/TiN) insert under different cutting parameters (cutting speed, feed rate, and depth of cut). Response surface methodology (RSM) and Analysis of variance (ANOVA) is employed to determine effect of the cutting parameters on four response variables (tooth pitch, saw height, chip width and chip thickness). Optimisation of each response variable is performed. The results indicate significant effect of all three cutting parameters on both the chip width and the chip thickness, significant effect of the feed rate and the depth of cut on both the tooth pitch and saw height, significant increase in the tooth pitch and saw height with increase in both the feed rate and the depth of cut, and significant increase in the chip width as well as chip thickness with increase in all three cutting parameters.

Keywords: hard turning; multilayer inserts; hard surface coatings; chip morphology; response surface methodology; RSM; optimisation; dry machining; alloy steel; cutting speed; feed rate; depth of cut; analysis of variance; ANOVA; tooth pitch; saw height; chip width; chip thickness; optimisation.

DOI: 10.1504/IJMMM.2015.073720

International Journal of Machining and Machinability of Materials, 2015 Vol.17 No.6, pp.481 - 506

Received: 08 Dec 2014
Accepted: 23 May 2015
Published online: 16 Dec 2015 *

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