Effect of Process Parameters on Tool Wear and Surface Roughness during Turning of Hardened Steel with Coated Ceramic Tool

Tool wear and surface roughness prediction plays a significant role in machining industry for proper planning and control of machining parameters and optimization of cutting conditions. This paper deals with developing a response surface method as a function of cutting parameters in turning of hardened AISI H13 steel (55 HRc) with PVD coated (Ti CN) ceramic tool under dry cutting condition. The mathematical models correlating the machining parameters with tool wear and surface roughness has been established. Plan of experiments was employed based on the central composite design (CCD) concept of response surface methodology (RSM) in order to data in controlled way. The obtained results reveal that cutting speed possesses the most dominating effect over tool wear followed by feed rate and depth of cut. Abrasion was the principal wear mechanism observed at higher cutting conditions. The feed rate is most significant parameter influences on surface roughness followed by depth of cut and cutting speed. The developed RSM models exhibited better proximity between predicted values and experimental values with 95% confidence intervals. The results imply that the model can be used easily to forecast tool wear and surface roughness in response to cutting parameters.