Hybrid optimal scheme for minimizing machining force and surface roughness in hard turning of AISI 52100 steel

Abstract

In the present work hard turning of AISI 52100 steel has been performed using PCBN tools. The input parameters considered are cutting speed, feed, depth of cut, Nose radius and negative rake angle and the measured responses are machining force (FM) and surface roughness (Ra). Experiments are planned as per Center Composite rotatable Design (CCD) of Response Surface Methodology (RSM). Investigative analysis on the effect of input parameters on the response is carried out using main effects plot and response surface plots. Further, a multi-objective optimization is performed with RSM and Grey Relational Analysis (GRA) integrated with Principle Component Analysis (PCA). Results demonstrated that negative rake angle is the paramount factor affecting the response followed by feed, speed, depth of cut, and nose radius. The optimum cutting parameters obtained are cutting speed 1000 rpm, feed 0.02 mm/rev, depth of cut 0.4 mm, Nose radius 1 mm and Negative rake angle 5°

Keywords: Hard turning, AISI 52100 steel, Machining force, Surface roughness, Grey relational analysis