Experimental investigation and modelling of surface roughness and resultant cutting force in hard turning of AISI H13 Steel

In recent years, turning of hardened steels has replaced grinding for finishing operations. This process is compared to grinding operations; hard turning has higher material removal rates, the possibility of greater process flexibility, lower equipment costs, and shorter setup time. CBN or ceramic cutting tools are widely used hard part machining. For successful application of hard turning, selection of suitable cutting parameters for a given cutting tool is an important step. For this purpose, an experimental investigation was conducted to determine the effects of cutting tool edge geometry, feed rate and cutting speed on surface roughness and resultant cutting force in hard turning of AISI H13 steel with ceramic cutting tools. Machining experiments were conducted in a CNC lathe based on Taguchi experimental design (L₁₆) in different levels of cutting parameters. In the experiments, a Kistler 9257 B, three cutting force components (Fc, Ff and Fr) piezoelectric dynamometer was used to measure cutting forces. Surface roughness measurements were performed by using a Mahrsurf PS1 device. For statistical analysis, analysis of variance has been performed and mathematical model have been developed for surface roughness and resultant cutting forces. The analysis of variance results showed that the cutting edge geometry, cutting speed and feed rate were the most significant factors on resultant cutting force while the cutting edge geometry and feed rate were the most significant factor for the surface roughness. The regression analysis was applied to predict the outcomes of the experiment. The predicted values and measured values were very close to each other. Afterwards a confirmation tests were performed to make a comparison between the predicted results and the measured results. According to the confirmation test results, measured values are within the 95% confidence interval.