International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

This paper presents an experimental study related to the optimization of cutting parameters in roughing turning of AISI 1045 steel under flooded conditions. The aim is to find a suitable combination of cutting parameters (cutting speed, depth of cut and feed rate) that minimize specific cutting energy and maximize material removal rate. The machining experiments were performed based on the Taguchi L27 full-factorial orthogonal array and response surface methodology (RSM) has been used to obtain the regression model for the specific cutting energy and material removal rate. Analysis of variance (ANOVA) was used to find out the significance of each cutting parameter. Finally, the developed models were interfaced with an artificial bee colony (ABC) to determine the optimal set of cutting parameters.

In this paper we have presented methodology for development of life prediction model for first order tool during turning of hardened 42CrMo4 steel at different levels of hardness. It is important to be able to predict and describe the tool life in regards to manufacturing costs during industrial production. Tool life is defined as the of cutting time that tool can be used. Cutting tools can be used when they do not reach tool life criteria and can produce parts with desired surface finish and dimensional accuracy. Flank wear of cutting tools is often selected as the tool life criterion because it determines the diametric accuracy of machining, its stability and reliability. Tool wear is defined as a gradual loss of tool material at contact zones of workpiece and tool material, resulting the cutting tool to reach its life limit. This paper investigates the tool wear of TiN coated tungsten carbide inserts under dry cutting, using the central composite design of experiments method (DoE) with three factors at three levels. By using the multiple linear regression analysis between cutting speed, feed rate and depth of cut, it determines the effects of cutting conditions on extended Taylor’s tool life equation.

The results of studies of the influence of the type of machining and tool material to the structural state of the surface layer and the fatigue strength of ХВСГsteel during machining are shown. Processing with the composite-10 tool in a surface layer for α – and γ – phases is accompanied only by compressing residual pressure while abrasive processing promotes occurrence of stretching pressure of an I-type. Increasing of cutting speed of the composite-10 tool from 50 to 200 m/min does not lead to significant changes in fatigue strength.