Abbas Adel T, El Rayes Magdy M, Luqman Monis, Naeim Noha, Hegab Hussien, Elkaseer Ahmed
Mechanical Engineering Department, College of Engineering, King Saud University, Riyadh 11421, P.O. Box 800, Saudi Arabia.
Department of Production Engineering and Mechanical Design, Port Said University, Port Fuad 42526, Egypt.
Materials (Basel). 2020 Apr 27;13(9):2036. doi: 10.3390/ma13092036.
This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.
本文报道了在不同切削条件下，使用传统圆刀片和修光刃刀片对AISI 4340合金钢进行精密车削时所产生的表面质量的实验评估。针对进给率、切削速度和切削深度采用了三因素（各有4个水平）全因子实验设计，加工后的表面质量以所得平均粗糙度（Ra）来表征。结果表明，在所提供的切削条件范围内，与传统刀片相比，使用修光刃刀片可获得更低的表面粗糙度值，这表明其性能更优。当将刀片类型作为一个定性因素纳入时，方差分析表明，刀片类型在决定表面粗糙度和材料去除率方面最为重要，进给率次之，其次是进给率与刀片类型的相互作用。研究发现，与使用传统刀片所能达到的全局最小值相比，使用修光刃刀片可在提高进给率、切削速度和切削深度的同时，提供更低Ra值的更好表面质量。这些发现表明，修光刃刀片能产生更好的表面质量，且材料去除率比传统刀片高出多达10倍。这清楚地表明，在对AISI 4340合金钢进行精密硬车削时，与传统圆头刀片相比，修光刃刀片在表面质量和生产率方面具有巨大优势。
