1.

Optimization of Surface Roughness of Bearing Steel during CNC Hard

Turning Process
International Journal of Engineering Trends and
Technology (IJETT)
2014 by IJETT Journal
Volume-17 Number-4
Year of Publication : 2014
Authors : Rony Mohan , Josephkunju Paul C , George Mathew
ABSTRACT: AISI 52100 is mainly used to manufacture bearings. The process
for manufacturing bearing includes turning process followed by three
different stages of grinding operation. Nowadays grinding operation are
replaced by hard turning process and it has been proved that hard turning
process are 30% cost effective. The machining parameters (cutting speed,
feed rate, depth of cut) are optimized with considerations of surface
roughness. Taguchis concepts of orthogonal arrays, signal to noise (S/N) ratio
and ANOVA are used to optimize the surface roughness for high speed CNC
turning process.

2. Analysis of surface roughness and cutting force components in hard

turning with CBN tool: Prediction model and cutting conditions optimization
journal ISSN :
DOI

0263-2241

10.1016/j.measurement.2011.11.011

publisher:Elsevier Science
authors: Hamdi Aouici, Mohamed Athmane Yallese, Kamel Chaoui, Tarek
Mabrouki, Jean-Franois Rigal
ABSTRACT:In this study, the effects of cutting speed, feed rate, workpiece
hardness and depth of cut on surface roughness and cutting force
components in the hard turning were experimentally investigated. AISI H11
steel was hardened to (40; 45 and 50) HRC, machined using cubic boron
nitride (CBN 7020 from Sandvik Company) which is essentially made of 57%
CBN and 35% TiCN. Four-factor (cutting speed, feed rate, hardness and depth
of cut) and three-level fractional experiment designs completed with a
statistical analysis of variance (ANOVA) were performed. Mathematical
models for surface roughness and cutting force components were developed
using the response surface methodology (RSM). Results show that the cutting
force components are influenced principally by the depth of cut and
workpiece hardness; on the other hand, both feed rate and workpiece

hardness have statistical significance on surface roughness. Finally, the

ranges for best cutting conditions are proposed for serial industrial
production.

3. Optimization of Tool Wear during High Speed Hard Turning of AISI 52100
Steel Alloys
International Journal of Engineering Trends and Technology
(IJETT)
2014 by IJETT Journal
Volume-17 Number-4
Year of Publication : 2014
Authors : Rony Mohan , Josephkunju Paul C , Issac Thamban
ABSTRACT:In this paper the combination of Taguchi method along with
analysis of variance was implemented for optimization of tool wear (tungsten
carbide) when high speed CNC hard turning of AISI 52100 steel alloy was
considered. The machining parameters cutting speed, feed rate, depth of cut
are optimized. Taguchis concepts of orthogonal arrays, signal to noise (S/N)
ratio, ANOVA etc are used and response table using the S/N ratios are
generated for optimization.

4. Key improvements in the machining of difficult-to-cut aerospace

superalloys. Int J Mach Tools Man
AUTHOR: E.O.EZEGWE Faculty of Engineering, Science and the Built
Environment, Machining Research Centre, School Engineering Systems and
Design, London South Bank University, 103 Borough Road, London SE1 0AA,
UK
International Journal of Machine Tools and Manufacture (Impact Factor: 2.74).
10/2005; 45(12-13):1353-1367. DOI: 10.1016/j.ijmachtools.2005.02.003
ABSTRACT:Significant advances have been made in understanding the
behaviour of engineering materials when machining at higher cutting
conditions from practical and theoretical standpoints. This approach has
enabled the aerospace industry to cope with constant introduction of new
materials that allow the engine temperature to increase at a rate of 10 C per
annum since the 1950s. Improvements achieved from research and
development activities in this area have particularly enhanced the machining

of difficult-to-cut nickel base and titanium alloys that have traditionally

exhibited low machinability due to their peculiar characteristics such as poor
thermal conductivity, high strength at elevated temperature, resistance to
wear and chemical degradation, etc. A good understanding of the cutting tool
materials, cutting conditions, processing time and functionality of the
machined component will lead to efficient and economic machining of nickel
and titanium base superalloys. This paper presents an overview of major
advances in machining techniques that have resulted to step increase in
productivity, hence lower manufacturing cost, without adverse effect on the
surface finish, surface integrity, circularity and hardness variation of the
machined component

5.Influence of Cutting Parameters on Cutting Force and Surface Finish in

Turning Operation
author: srihari pillai
ABSTRACT: This research reports the significance of influence of speed, feed
and depth of cut on cutting force and surface roughness while working with
tool made of ceramic with an Al2O3+TiC matrix (KY1615)and the work
material of AISI 1050 steel (hardness of 484 NV). Experiments were
conducted using Johnford TC35 Industrial type of CNC lathe. Taguchi method
(L27 design with 3 levels and 3 factors) was used for the experiments.
Analysis of variance with adjusted approach has been adopted. The results
have indicated that it is teed rate which has significant influence both on
cutting force as well as surface roughness. Depth of cut has a significant
influence on cutting force, but has an insignificant influence on surface
roughness. The interaction of feed and depth of cut and the interaction of all
the three cutting parameters have significant influence on cutting force,
whereas, none of the interaction effects are having significant influence on
the surface roughness produced. If power consumption minimization is to be
achieved for the best possible surface finish, the most recommended
combination of feed rate and depth of cut is also determined. (C) 2013 The
Authors. Published by Elsevier Ltd. Selection and peer-review under
responsibility of the organizing and review committee of IConDM 2013

6. Investigation on the Turning Parameters for Surface Roughness using

Taguchi Analysis
AUTHOR:T. Rajasekarana, , K. Palanikumarb, S. Arunachalamc
ABSTRACT:One of the important interests in the machining is attaining

better surface roughness as well as dimensional accuracy. Polymer materials

are continuously displacing the conventional materials. Their machining
behavior is different in many aspects from machining of conventional metallic
materials. Polymer based composite materials have superior properties for
mechanical strength and stiffness, such as high strength-to-weight ratio and
high stiffness-to-weight ratio. Fiber reinforced polymer composite materials
are the one which are produced closer to the required shape, further
machining is often necessary to achieve expected surface characteristics.
This experimental study targets the machining of carbon fiber reinforced
polymer material made into the form of tube. It examines various process
parameters such as cutting speed, feed and depth of cut and their
importance in deciding the surface roughness. Surface roughness was
measured after machining is carried out under specified machining
conditions. This experimental study focuses on the prediction of machining
parameters that yield better surface characteristics in order to avoid
machining of hard materials such as fiber reinforced composite materials so
that enormous money spent in machining could be saved to some extent. For
prediction this experimental study makes use of response surface
methodology. The Taguchi method is used to solve many engineering
problems. This work uses the Taguchi's orthogonal array method to find out
the number of experiments to be carried out for turning operations. Also the
analysis of variance is used to investigate the cutting parameters. In addition
to the optimal cutting parameters for turning operations, the main cutting
parameter that affect the cutting performance in turning operations could be
found out
7.Effect of nose radius and tool wear on residual stress distribution in hard
turning of bearing steel. J Mater Process Technol 150:234-241 akira tsukuda
authors: meng liu,jun ichiro takagi,akira tsukuda
ABSTRACT: This study presents a experimental investigation to clarify the
effects of tool nose radius and tool wear on residual stress distribution in hard
turning of bearing steel JIS SUJ2. Three types of CBN tools with different nose
radius (0.4, 0.8 and 1.2 mm) were used in this study. The residual stresses
beneath the machined surface were measured using X-ray diffraction
technique and electro-polishing technique. The results obtained in this study
show that the tool nose radius affects the residual stress distribution
significantly. Especially the effect on the residual stresses at the machined
surface at early stage of cutting process is remarkable. For the tool wear, as
the tool wear increases, the residual stress at the machined surface shifts to
tensile stress range and the residual compressive stress beneath the
machined surface increases greatly.

8.Influence of surface texture and roughness parameters on friction and

transfer layer formation during sliding of aluminium pin on steel plate
authors: kishor,satish vasu khailash,pradeep l menezes
ABSTRACT: Surface texture of harder mating surfaces plays an important role
during sliding against softer materials and hence the importance of
characterizing the surfaces in terms of roughness parameters. In the present
investigation, basic studies were conducted using inclined pin-on-plate sliding
tester to understand the surface texture effect of hard surfaces on coefficient
of friction and transfer layer formation. A tribological couple made of a super
purity aluminium pin against steel plate was used in the tests. Two surface
parameters of steel plates, namely roughness and texture, were varied in the
tests. It was observed that the transfer layer formation and the coefficient of
friction along with its two components, namely, the adhesion and plowing,
are controlled by the surface texture and are independent of surface
roughness (Ra). Among the various surface roughness parameters, the
average or the mean slope of the profile was found to explain the variations
best. Under lubricated conditions, stickslip phenomena was observed, the
amplitude of which depends on the plowing component of friction. The
presence of stickslip motion under lubricated conditions could be attributed
to the molecular deformation of the lubricant component confined between
asperities.

9. Optimization of Surface Roughness of Bearing Steel during CNC Hard

Turning Process

International Journal of Engineering Trends and Technology

(IJETT)
2014 by IJETT Journal
Volume-17 Number-4
Year of Publication : 2014
Authors : Rony Mohan , Josephkunju Paul C , Issac Thamban
abstract: AISI 52100 is mainly used to manufacture bearings. The process for
manufacturing bearing includes turning process followed by three different
stages of grinding operation. Nowadays grinding operation are replaced by
hard turning process and it has been proved that hard turning process are
30% cost effective. The machining parameters (cutting speed, feed rate,

depth of cut) are optimized with considerations of surface roughness.

Taguchis concepts of orthogonal arrays, signal to noise (S/N) ratio and
ANOVA are used to optimize the surface roughness for high speed CNC
turning process.

10. Mechanical and wear behaviors of Al12Si XMg composites reinforced

with in situ Mg 2Si particles
AUTHORS: hayrettin, Karabk University, Engineering Faculty, Karabuk
78050, Turkey
Materials and Design (Impact Factor: 3.5). 05/2011; 32(5):2983-2987. DOI:
10.1016/j.matdes.2011.01.009
ABSTRACT:A study has been conducted to investigate the mechanical and
wear behaviors of the Al12SiXMg alloys (where Mg contents were 5%, 10%
and 20%) cast by adding modifiers such as Sr, red phosphorous and salt
mixtures. Mechanical properties were determined by hardness
measurements, compression and wear tests. Reciprocating wear tests were
conducted by rubbing ceramic (Al2O3) and steel (AISI 52100) balls on the
unlubricated surfaces by applying the normal load of 2N. The microstructure
of the Al12SiXMg alloys consisted of the Si needles and Mg2Si precipitates
(two morphologies of which are polyhedral shape dark particles and grey
colored components of Chinese script) in the Al matrix. Results demonstrated
that volume fraction and size of the primary Mg2Si particles increased with
increasing the Mg content. Mg containing alloys exhibited higher hardness
and better wear resistance than the Mg free alloy.