Comparison between mixed ceramic and reinforced ceramic tools in terms of cutting force components modelling and optimization when machining hardened steel AISI 4140 (60 HRC)

¹ Département de Construction Mécanique et Productique (CMP), FGM&GP, Université des Sciences et de la Technologie Houari Boumediene (USTHB), BP 32 El-Alia, Bab-Ezzouar, 16111 Alger, Algérie
² Laboratoire Mécanique Appliquée des Nouveaux Matériaux (LMANM), Université 08 mai 1945-Guelma, BP 401, 24000 Guelma, Algérie
³ École Nationale Supérieure de Technologie (ENST) – ex CT siège DG. SNVI, R. N° 5 Z.I. Rouiba, Alger, Algérie
⁴ Laboratoire Mécanique et Structures (LMS), Université 08 mai 1945-Guelma, BP 401 Guelma, 24000, Algérie
⁵ LRTAPM, Université Badji-Moukhtar, BP 12, 23000 Annaba, Algérie

^a Corresponding author: fbrahim@yahoo.fr

Received: 23 June 2014
Accepted: 17 May 2015

Abstract

This paper describes a comparison between mixed ceramic [Al₂O₃ (70%) + TiC (30%)] and reinforced ceramic [Al2O₃ (75%) + SiC (25%)] tools in terms of cutting force components when machining in dry hard turning AISI 4140 steel, hardened to 60 HRC. The response surface methodology (RSM) and the analysis of variance (ANOVA) are applied to investigate effects of cutting speed, feed rate and depth of cut on cutting force components in order to model and optimize these technological parameters. Results of this study indicate that the machining with the mixed ceramic insert generates lower values of cutting force components than reinforced ceramic insert. Consequently, the mixed ceramic CC650 is the most powerful tool. The developed models can be used in the metal machining industries and would be helpful in selecting cutting variables for optimization of hard cutting process.