Title: An investigation to study the wear characteristics and comparative performance of cutting inserts during hard turning

Authors: Ramanuj Kumar; Ashok Kumar Sahoo; Purna Chandra Mishra; Rabin Kumar Das

Addresses: School of Mechanical Engineering, KIIT University, Bhubaneswar-24, Odisha, India ' School of Mechanical Engineering, KIIT University, Bhubaneswar-24, Odisha, India ' School of Mechanical Engineering, KIIT University, Bhubaneswar-24, Odisha, India ' School of Mechanical Engineering, KIIT University, Bhubaneswar-24, Odisha, India

Abstract: The present work emphasise on comparative hard turning performances and wear characteristics of coated carbide and ceramic inserts for AISI D2 steel (55 ± 1 HRC). It is revealed that average surface roughness for both tools are below 1.6 μm with significant effect of feed. Abrasion, diffusion and notching are principal wear mechanism for coated carbide whereas no catastrophic failure, fracturing and chipping are observed in ceramic inserts and characterised by good stability in machining. Saw tooth chips with severe serrations are observed due to the periodic development of cracks. Tool life of coated carbide and ceramic inserts are 52 and 60 minutes at their optimal levels through flank wear limit of 0.15 mm. Ceramic insert performs well at higher cutting speed over coated carbide insert and is observed to be economical. However, if higher material removal rate is not a principal criterion, coated carbide tool performs better at low cutting conditions.

Keywords: hard turning; multilayer coated carbide; ceramic; machinability; wear; grey relational analysis; cost analysis; surface roughness.

DOI: 10.1504/IJMMM.2018.094730

International Journal of Machining and Machinability of Materials, 2018 Vol.20 No.4, pp.320 - 344

Received: 07 Jun 2017
Accepted: 09 Sep 2017
Published online: 14 Sep 2018 *

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