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Effect of Cutting Parameters in Hard Turning on Chip Formation and Machined Surface

Shambhu Choubisa, B. P. Nandawana, M. A. Saloda, M. S. Khidiya


Cost effectiveness, increasing demand, high production rates and reliability of the product have increased the potential of industrial application of hard turning technology during the past few years. Grinding operation for hard steel component reduces the machining sequence, the machining time and the specific cutting energy. Hard turning also shows effects like generation of high temperature, the formation of saw toothed chips. In this thesis, experimental investigation is conducted in order to study the chip transition using Scanning Electron Microscopy and chip micro-hardness were conducted to correlate the chip morphology, cutting forces using micro-hardness tester. The surface integrity of machines part is also investigated. This study focuses on surface and sub-surface defects and white layer formation. The machined surfaces are examined using SEM to study effect of different process parameters on the quality of the machined surface. Cutting forces were measured by lathe tool dynamometer and ANOVA test were performed to observe the effect of cutting parameters on cutting forces.

Keywords: AISI D2 steel, chip formation, cutting forces, hard turning, microstructure of machined surface ANOVA

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