An optimization investigation on surface roughness and its evolution with tool wear in dry turning of boron alloy cast iron

Abstract

Boron alloy cast iron (BACI) with good mechanical properties is usually used as cylinder liner material for heavy-duty diesel engines. Fine surface finish is often required for the machined surface of BACI cylinder liners. This study is mainly focused on the cutting parameters optimization on surface roughness and its evolution with tool wear in dry turning of BACI. Response surface methodology (RSM) involving central composite design is employed in the optimization of cutting parameters on surface roughness. An optimization parameter is determined with the consideration of the surface roughness and machining efficiency. The evolutions of tool wear and surface roughness are also investigated during BACI turning by using uncoated and PVD-TiAlN coated carbide inserts. The results indicate that RSM is effective for the optimization of cutting parameters on surface roughness. It is also confirmed that the PVD-TiAlN coated insert showed a good performance with long tool life and steady surface quality during BACI turning process.