Comparative Performance In Hard Turning Of AISI 1015 Steel With Carbide Insert Using Orthogonal Array Design And Grey Relational Analysis Under Spray Impingement Cooling And Dry Environment

Abstract

This study investigates the effects of cutting parameters on surface roughness (Ra), cutting temperature (T0C) at the chip tool interface and the material removal rate (MRR mm3/min) during hard machining of AISI 1015 (43 HRC) steel using carbide insert under dry and spray impingement cooling environment. A combined technique using orthogonal array and analysis of variance (ANOVA) was employed to investigate the contribution of spindle speed, feed rate, depth of cut and air pressure on responses. Utilization of IR camera is been effective to calculate the temperature at the interface of workpiece and the tool. It is observed that with spray impingement cooling, cutting performance improves compared to dry cutting. The predicted multi response optimization setting (N3-f1-d1-P2) ensures minimization of surface roughness, cutting temperature and maximization of material removal rate. Finally optimal result was validated by confirmatory test and the improvement in grey relational grade was found to be 0.288.