Experimental investigation of cutting zone temperature and flank wear correlation in turning AISI 1045 steel with different tool geometries

Abstract

This paper focuses on the experimental investigation and analysis of temperature generated at the cutting zone during machining and the wear of cutting insert at the flank face and the relationship between these parameters. Uncoated cemented carbide inserts of different geometries are used to turn AISI 1045 steel. Three levels of cutting insert geometries cutting insert shape (included angle), relief angle and nose radius are chosen. Taguchi’s design of experiments (DoE) is used to design the experiments and using signal-to-noise (S/N) ratio, the control parameters are analyzed, showing a correlation between the two responses. Analysis of variance is performed to determine the most significant factor over the responses and empirical models are developed for predicting the responses using multiple linear regression models. Cutting zone temperature is mostly influenced by nose radius followed by cutting insert shape and for flank wear the significance of cutting insert shape is more, followed by nose radius. Confirmation experiment performed with optimum cutting insert geometry shows a reduction in cutting zone temperature and flank wear.