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Experimental and Analytical Based Investigations on Machinability of High-Chrome White Cast Iron Using CBN Tools

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Abstract

High-chrome white cast iron (HCWCI) is one of the hardest metals used in the process and mining industries faces tough challenge in metal cutting. Focusing on this issue, influence of cutting parameters (e.g., cutting speed, depth of cut, feed rate) on machinability characteristics (e.g., cutting forces, surface roughness, material removal rate, machining power) of HCWCI has been investigated by experimentally and analytically using cubic boron nitride (CBN) cutting tools. Experimentation is carried out in conjunction with the Taguchi techniques and the influence of each cutting parameter of the process has been analyzed by analytical tools; analysis of variance, regression technique and artificial neural networks (ANNs). The study reveals depth of cut has the highest contribution on the cutting forces, and cutting speed on surface roughness and machining power. The confirmation test identifies both regression and ANN techniques are the most effective tools to evaluate machinability characteristics of HCWCI. Further, the CBN cutting tool exhibits excellent performance in machining of HCWCI.

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Abbreviations

AISI:

American Iron and Steel Institute

BHN:

Brinell hardness number

CBN:

Cubic boron nitride cutting tool

DF:

Degrees-of-freedom

d :

Depth of cut (mm)

f :

Feed rate (mm/rev)

F :

Statistical characteristics

F c :

Main cutting force (N)

F f :

Feed force (N)

F t :

Thrust force (N)

HRC:

Hardness value by Rockwell

MRR :

Material removal rate (mm3/min)

MS:

Mean of squares

MSE:

Mean square error

P m :

Machining power (kW)

P value:

Percentage of contribution value

R a :

Average surface roughness (µm)

\( R^{2}(\rm adj) \) :

Adjusted coefficient of multiple correlation

S :

Cutting speed (m/min)

SS:

Sum of squares

S/N ratio:

Signal-to-noise ratio

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore, 575025, India

    A. M. Ravi & S. M. Murigendrappa

  2. Department of Metallurgical & Materials Engineering, Indian Institute of Technology, Kharagpur, 721302, India

    P. G. Mukunda

Authors
  1. A. M. Ravi
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  2. S. M. Murigendrappa
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  3. P. G. Mukunda
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Correspondence to S. M. Murigendrappa.

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Ravi, A.M., Murigendrappa, S.M. & Mukunda, P.G. Experimental and Analytical Based Investigations on Machinability of High-Chrome White Cast Iron Using CBN Tools. Trans Indian Inst Met 68, 61–77 (2015). https://doi.org/10.1007/s12666-014-0431-6

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