Machinability evaluation in hard turning of cold work tool steel

(D2) with ceramic tools using statistical techniques

J. Paulo Davim
*
, Lu s Figueira
Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal
Received 13 June 2005; accepted 16 January 2006
Available online 7 March 2006
Abstract
Turning hardened tool steel using ceramic cutting tool, has certain advantages over the traditional turning/hardening/cylindrical
grinding practice in terms of increased productivity and reduced power consumption. The hard turning is generally performed without
a coolant (additional environmental advantage).
An experimental investigation was carried out using ceramic cutting tools, composed approximately with (70%) of Al
2
O
3
and (30%) of
TiC, in surface nish operations on cold work tool steel D2 (AISI) heat treated to a hardness of 60 HRC.
A plan of experiments, based on orthogonal arrays, was made in turning with prexed cutting parameters in tool steel workpieces. A
combined technique using orthogonal array and analysis of variance (ANOVA) was employed to investigate the machinability of cold
work tool steel. The results of the tests shows that with a appropriate cutting parameters choice is possible to obtain a surface roughness
(R
a
< 0.8 lm) that allows to eliminate cylindrical grinding operations.
2006 Elsevier Ltd. All rights reserved.
Keywords: Machinability; Hard turning; Ceramic tools; Tool wear; Specic cutting pressure; Surface roughness
1. Introduction
Ceramic tools are widely used in the manufacturing
industry for the machining of various hard materials. Inter-
est in ceramics as a high speed cutting tool material is based
primarily on favourable material properties. As a class of
materials, ceramics possess high melting point, excellent
hardness and good wear resistance. Unlike most metals,
hardness levels in ceramics generally remain high at ele-
vated temperature which means that cutting tip integrity
is relatively unaected at high cutting speeds [1].
The works of various authors [210], when reporting the
performance of ceramic and cubic boron nitride (CBN)
tools in the machining of various hard materials, have
shown that the surface quality (surface roughness), tool
wear, and cutting forces (feed force, depth force and cut-
ting force) are dependent on cutting parameters (cutting
velocity and feed rate) and tool geometry.
Luo et al. [2] showed that the main wear abrasion
mechanism for the CBN tools was the abrasion of the
blinder material by the hard carbide particles of the work-
piece. For the ceramic tools, there was adhesive and abra-
sive wear. It was also found that a protective layer formed
on the chip-tool interface was formed. This layer plays a
important role in the wear behaviour of CBN and ceramic
tools.
Othani and Yokogawa [3] stated that the cold wear
mechanism of CBN and ceramic tools in the machining
of cold work tool steel is abrasion by hard alloy carbide
particles contained in the workpiece.
Obikawa et al. [4] investigated quantitatively the crater
wear characteristic of alumina (Al
2
O
3
) ceramic tool based
on the stress and temperature on the rake face. The
obtained wear characteristic indicated that the sintered alu-
mina ceramic had several times higher to crater wear than
0261-3069/$ - see front matter 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2006.01.011
*
Corresponding author. Fax: +351 234 370953.
E-mail address: pdavim@mec.ua.pt (J.P. Davim).
www.elsevier.com/locate/matdes
Materials and Design 28 (2007) 11861191
Materials
& Design
the CVD layer of alumina coated on the cemented carbide
on the same conditions (temperature and stress).
DErrico et al. [5] investigated the cutting performances
of dierent ceramic grades (oxide nitride, mixed and whis-
ker reinforced ceramics) in terms of wear resistance,
mechanical toughness and resistance to thermal shock.
Experimental results are discussed with application to turn-
ing of work material (nickel based alloy, tempered steel and
grey cast iron) with diverse machinability.
Xu et al. [6] showed in detail the eect of yttrium on the
mechanical properties and machining performance of
AL
2
O
3
/Ti(C,N) ceramic tool. Results show that the ade-
quately addition of yttrium improves the mechanical prop-
erty of the ceramic tool material.
Barry and Byrne [7,8] investigated the mechanism of
AL
2
O
3
/TiC cutting tool wear in the nish turning of hard-
ened steels with particular cognizance of the work material
inclusion content. The rate of tool wear appears to be
determined by the hard inclusion contend or alloy carbide
content of the work material. a new mechanism is proposed
to account for the superior wear resistance of CBN/TiC
composites in comparison to high-content CBN tools in
the nish machining of 4340 (AISI) steel of 52 HRC.
Grzesik et al. [9] studied the contribution to surface
roughness generation when turning a low chromium alloy
steel, heat treated to a hardness of 60 HRC, with ceramic
cutting tools and cylindrical grinding. The comparison
between bearing area curves obtained for these machining
processes was done in order to replace cylindrical grinding
by hard turning.
Yang et al. [10] used the Taguchi method to nd the
optimal cutting parameters for turning operations. An
orthogonal array and the analysis of variance (ANOVA)
are employed to investigate the cutting characteristics using
cemented carbide cutting tools. Through this study, not
only can the optimal cutting parameters for turning opera-
tions be obtained, but also the main cutting parameters
that aect the cutting performance in turning operations
can be found. Experimental results are provided to conrm
the eectiveness of this approach.
Recently, Lima et al. [11] investigated the machinability
of hardened steels at dierent levels of hardness and using a
range of cutting tool materials. More specically the
machinability of hardened AISI 4340 high strength low
alloy steel and AISI D2 cold work tool steel. The results
indicated that when turning AISI 4340 steel the surface
roughness of the machined parts was improved as cutting
speed was elevated and deteriorated with feed rate. Depth
of cut presented little eect on the surface roughness val-
ues. Turning AISI D2 steel with mixed alumina inserts
allowed a surface nish as good as that produced by cylin-
drical grinding.
The current article investigates the inuence of cutting
parameters (V and f) under ank wear (VC), specic cutting
pressure (K
s
) and surface roughness (R
a
) on machinability
evaluation in turning of cold work tool steel hardened with
ceramic tools using analysis of variance (ANOVA).
2. Experimental procedure
2.1. Means and materials
The main aim of this experimental work was the establishment of the
correlation between cutting parameters and machinability, such as surface
roughness, specic cutting pressure and ank tool wear, aiming at simulat-
ing them for surface nish.
Machining experiments were performed using a high rigidly lathe
Kingsbury50 CNC with 18 kW spindle power and a maximum spindle
speed of 4500 rpm.
All results were obtained on an high chromium cold work tool steel D2
(AISI) with the following chemical composition: 1.55% C; 0.30% Si; 0.40%
Mn; 11.80% Cr; 0.80% Mo and 0.80% V. Fig. 1 shows the transversal
hardness performance measured on the workpieces hardened by quench-
ing (after vacuum treatment) between 1000 and 1040 C.
The geometry of the workpiece used allowed a xation with a length
of 30 mm, to obtain a cylindrical turning length (L) with a 200 mm, with
a initial diameter of 50 mm (D) corresponding to ratio (L/D) 4. The nal
ratio (L/D) of the workpiece was approximately 8 in order to assure the
necessary stiness of the elastic xed system chuck/piece/cutting tool.
Type insert ceramics tools CNMA 120408 T01020 CC650 were used to
machining the tool steel with a geometry as follow: rake angle 6 (nega-
tive), 5 clearance angle, 80 edge major tool cutting and 0 cutting edge
inclination angle (Fig. 2). Type PCLNL2020K12 (ISO) tool holder was
used. The depth of cut (doc) in both cold work tool steel D2 (AISI) was
0.2 mm.
45
55
65
-25 -20 -15 -10 -5 0 5 10 15 20 25
Distance from center transversal workpiece section[mm]
R
o
c
k
w
e
l
l

h
a
r
d
n
e
s
s

H
R
C
Fig. 1. Example of the rockwell hardness distribution on the transversal
workpiece section.
Fig. 2. Ceramic insert geometry.
J.P. Davim, L. Figueira / Materials and Design 28 (2007) 11861191 1187
The measurement of the arithmetic roughness average (R
a
) on turning
surfaces, was made by a prolometer Hommelwerke

T1000, with a cut

o of 0.8 mm, according ISO/DIS 4287/1E.
The acquisition of the cutting forces as well the determination specic
cutting pressure (K
s
), was made by a dynamometer piezoelectric Kistler

9121, capable to measure simultaneous all orthogonal forces developed

in turning operations.
The value of specic cutting pressure (K
s
) was calculated by the follow-
ing equation:
K
s
F
c
=S 1
being, F
c
the main cutting force in N, and S the chip section in mm
2
.
The evaluation the ank tool wear was made by a shop microscope
Mitutoyo

TM-500 with 30 magnication and 1 lm resolution. The

admissible wear was established according standard ISO 3685 and mea-
sured at corner radius (VC). The determination of ank wear was made
as shown in Fig. 3.
2.2. Plan of experiments/analysis of variance
Orthogonal array was applied for the execution of the plan of experi-
ments, for three levels, whereby the levels are the values taken by the fac-
tors. The factors to be studied and the attribution of the respective levels
are indicated in Table 1.
The chosen array was the L27, which has 27 rows corresponding to the
number of tests (26 degrees of freedom) with 13 columns at three levels, as
shown in Table 2. The factors and the interactions are assigned to the
columns.
The rst column of the table was assigned to the cutting velocity
(V
c
), the second to the feed rate (f), the fth to the cutting time (t
c
)
and the remaining were assigned the interactions. The outputs to be
studied are the arithmetic mean roughness (R
a
), specic cutting pressure
(K
s
) and ank tool wear (VC). In order to allow the analysis of the
variance, each test was repeated two times, corresponding a total of
54 tests.
The main purpose of ANOVA is the application of a statistical tech-
nique to identify the eect of factors. Results from ANOVA can determine
very clearly the impact of each factor on the outputs. The parameter sym-
bols typically used in orthogonal array and ANOVA are described in
[12,13,1,14].
3. Results and discussion
Machinability refers to the ease or diculty with which
a given material can be machined. The machinability was
evaluated by specic cutting pressure (K
s
) in operation, sur-
face roughness (R
a
) in workpiece and ank wear (VC) on
cutting tool.
3.1. Graphic analysis
In Fig. 4, the evolution of the ank tool wear (VC) with
the feed for dierent cutting velocities can be seen. From
Fig. 4, it can be realized that the VC increases with cutting
velocity. For a cutting velocity of 220 m/min the VC
Fig. 3. Flank wear (VC) determination according ISO3685.
Table 1
Attribution levels of cutting factors
Level Cutting velocity
V
c
(m/min)
Feed rate
f (mm/rev)
Cutting time
t
c
(min)
1 80 0.05 5
2 150 0.10 10
3 220 0.15 15
Table 2
Orthogonal array L
27
(3
13
) [12]
L
27
(3
13
) test 1 2 3 4 5 6 7 8 9 10 11 12 13
1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 1 1 1 1 2 2 2 2 2 2 2 2 2
3 1 1 1 1 3 3 3 3 3 3 3 3 3
4 1 2 2 2 1 1 1 2 2 2 3 3 3
5 1 2 2 2 2 2 2 3 3 3 1 1 1
6 1 2 2 2 3 3 3 1 1 1 2 2 2
7 1 3 3 3 1 1 1 3 3 3 2 2 2
8 1 3 3 3 2 2 2 1 1 1 3 3 3
9 1 3 3 3 3 3 3 2 2 2 1 1 1
10 2 1 2 3 1 2 3 1 2 3 1 2 3
11 2 1 2 3 2 3 1 2 3 1 2 3 1
12 2 1 2 3 3 1 2 3 1 2 3 1 2
13 2 2 3 1 1 2 3 2 3 1 3 1 2
14 2 2 3 1 2 3 1 3 1 2 1 2 3
15 2 2 3 1 3 1 2 1 2 3 2 3 1
16 2 3 1 2 1 2 3 3 1 2 2 3 1
17 2 3 1 2 2 3 1 1 2 3 3 1 2
18 2 3 1 2 3 1 2 2 3 1 1 2 3
19 3 1 3 2 1 3 2 1 3 2 1 3 2
20 3 1 3 2 2 1 3 2 1 3 2 1 3
21 3 1 3 2 3 2 1 3 2 1 3 2 1
22 3 2 1 3 1 3 2 2 1 3 3 2 1
23 3 2 1 3 2 1 3 3 2 1 1 3 2
24 3 2 1 3 3 2 1 1 3 2 2 1 3
25 3 3 2 1 1 3 2 3 2 1 2 1 3
26 3 3 2 1 2 1 3 1 3 2 3 2 1
27 3 3 2 1 3 2 1 2 1 3 1 3 2
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 0.05 0.1 0.2 0.15
Feedrate - f (mm/rev.)
T
o
o
l

w
e
a
r
-

V
C
(
m
m
)
Vc=80m/min
Vc=150m/min
Vc=220m/min
Fig. 4. Flank wear width of ceramic tools vs. feed rate at various cutting
velocities.
1188 J.P. Davim, L. Figueira / Materials and Design 28 (2007) 11861191
increase signicantly in comparison with all others velocity
tests. The eect of abrasion mechanisms determinate faster
failure veried on ank tool wear.
In Fig. 5, the evolution of the specic cutting pressure
(K
s
) with the feed for several cutting velocities values is
shown. Increase feed rate change the cross-sectional area
of the uncut chip and reduces the K
s
.
Fig. 6 shows the evolution of the arithmetic mean
roughness (R
a
) as a function of the feed, for several cutting
velocities. According to the graph, it can be seen that the
R
a
increases with the feed, and decreases with the cutting
velocity.
3.2. Statistical analysis
An data analysis of variance with tool wear (VC), spe-
cic cutting pressure (K
s
) and arithmetic mean roughness
(R
a
), was made with the objective of analysing the inuence
of the cutting velocity (V
c
), the feed rate (f) and the cutting
time (t
c
) on the total variance of the results.
The results of tool wear (VC), specic cutting pressure
(K
s
) and arithmetic mean roughness (R
a
) using orthogonal
array are shown in Tables 35, respectively.
Tables 68 show the results of ANOVA, respectively,
for VC, K
s
and R
a
. This analysis was carried out for a
5% signicance level, i.e., for a 95% condence level. The
last column of the tables shows the percentage of each fac-
tor contribution (P %) on the total variation, thus indicat-
ing the degree of inuence on the result.
From the analysis of Table 6, it can be apparent seen
that the cutting velocity factor (P 57.4%) and the cutting
time factor (P 13.4%) have statistical signicance on the
tool wear (VC), especially the cutting velocity factor. The
feed rate factor and the interactions does not present a sta-
tistical signicance on the tool wear (VC).
Equally from Table 7, it can be seen that the feed rate
factor (P 64.1%) have statistical signicance on the spe-
cic cutting pressure (K
s
). The cutting velocity, cutting time
and the interactions does not present a statistical signi-
cance on the specic cutting pressure (K
s
).
Finality from Table 8, it can be realized that the cutting
time factor (P 32%) and the feed rate factor (P 29.6%)
have statistical signicance on the arithmetic mean rough-
ness (R
a
). The cutting velocity factor and interactions does
not present a statistical signicance on the arithmetic mean
roughness (R
a
).
It should be noticed that the error associated to the
ANOVA tables has, respectively, 11.1%, 4.8% and 12.5%
for tool wear (VC), specic cutting pressure (K
s
) and arith-
metic mean roughness (R
a
).
0
1000
2000
3000
4000
5000
6000
S
p
e
c
i
f
i
c

c
u
t
t
i
n
g

p
r
e
s
s
u
r
e

-

K
s
(
N
/
m
m
2
)
0 0.05 0.1 0.2 0.15
Feedrate - f (mm/rev.)
Vc=80m/min
Vc=150m/min
Vc=220m/min
Fig. 5. Specic cutting pressure vs. feed rate at various cutting velocities.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
A
r
i
t
h
m
e
t
i
c
s

r
o
u
g
h
n
e
s
s

a
v
e
r
a
g
e

-
R
a
(

m
)
0 0.05 0.1 0.2 0.15
Feedrate - f (mm/rev.)
Vc=80m/min
Vc=150m/min
Vc=220m/min
Fig. 6. Arithmetic roughness average vs. feed rate at various cutting
velocities.
Table 3
Orthogonal array for VC
Test V
c
(m/min) f (mm/rev) t
c
(min) y
1
y
2
VC
a
1 80 0.05 5 0.054 0.061 0.058
2 80 0.05 10 0.081 0.080 0.081
3 80 0.05 15 0.111 0.097 0.104
4 80 0.10 5 0.047 0.049 0.048
5 80 0.10 10 0.077 0.082 0.080
6 80 0.10 15 0.085 0.090 0.088
7 80 0.15 5 0.035 0.030 0.033
8 80 0.15 10 0.081 0.080 0.081
9 80 0.15 15 0.098 0.094 0.960
10 150 0.05 5 0.091 0.110 0.101
11 150 0.05 10 0.140 0.140 0.140
12 150 0.05 15 0.157 0.150 0.540
13 150 0.10 5 0.086 0.078 0.082
14 150 0.10 10 0.150 0.132 0.141
15 150 0.10 15 0.256 0.243 0.250
16 150 0.15 5 0.103 0.094 0.099
17 150 0.15 10 0.172 0.180 0.176
18 150 0.15 15 0.241 0.245 0.243
19 220 0.05 5 0.344 0.334 0.339
20 220 0.05 10 0.600 0.594 0.597
21 220 0.05 15 0.648 0.635 0.642
22 220 0.10 5 0.190 0.210 0.200
23 220 0.10 10 0.290 0.310 0.300
24 220 0.10 15 0.310 0.330 0.320
25 220 0.15 5 0.180 0.195 0.188
26 220 0.15 10 0.280 0.310 0.225
27 220 0.15 15 0.750 0.800 0.775
Average 0.210 0.213 0.211
a
VC
1
2
y
1
y
2
.
J.P. Davim, L. Figueira / Materials and Design 28 (2007) 11861191 1189
4. Conclusions
Based on this work, the following conclusions may be
drawn for the cutting parameters used and the character-
isation of the machinability evaluation in hard turning of
cold tool work steel (D2) using ceramic tools:
The tool wear is highly inuenced by the cutting velocity
(57.4%) and, in a smaller degree, by cutting time
(13.4%).
The excessive ank tool wear existent in the ceramic
tools, which works with high cutting velocity has a cor-
respondent reduction on surface roughness.
Table 4
Orthogonal array for K
s
Test V
c
(m/min) f (mm/rev) t
c
(min) y
1
y
2
K
s
a
1 80 0.05 5 4273.9 4255.2 4264.6
2 80 0.05 10 4248.6 4005.6 4127.1
3 80 0.05 15 4396.5 3155.3 3775.9
4 80 0.10 5 2901.3 2843.2 2872.2
5 80 0.10 10 3190.0 3085.7 3137.8
6 80 0.10 15 3280.8 3156.8 3218.8
7 80 0.15 5 2367.2 2274.3 2320.8
8 80 0.15 10 2553.9 2520.1 2537.0
9 80 0.15 15 2704.9 2638.0 2671.4
10 150 0.05 5 3605.4 4010.5 3808.0
11 150 0.05 10 4020.0 4324.7 4172.4
12 150 0.05 15 4365.2 4215.1 4290.2
13 150 0.10 5 2879.5 2808.3 2843.9
14 150 0.10 10 3124.9 3046.1 3085.5
15 150 0.10 15 3531.2 3778.3 3654.7
16 150 0.15 5 2482.0 2513.0 2497.5
17 150 0.15 10 2780.3 2542.4 2661.4
18 150 0.15 15 3086.1 3175.8 3131.0
19 220 0.05 5 5785.2 3782.2 4783.7
20 220 0.05 10 5121.6 4952.6 5037.1
21 220 0.05 15 5619.2 5561.6 5590.4
22 220 0.10 5 3065.4 3187.9 3126.6
23 220 0.10 10 3697.8 3814.9 3756.3
24 220 0.10 15 4251.3 4522.6 4386.9
25 220 0.15 5 2606.1 2705.5 2655.8
26 220 0.15 10 3132.4 3136.0 3134.2
27 220 0.15 15 3109.0 3109.1 3109.1
Average 3562.2 3448.9 3505.6
a
K
s

1
2
y
1
y
2
.
Table 5
Orthogonal array for R
a
Test V
c
(m/min) f (mm/rev) t
c
(min) y
1
y
2
R
a
a
1 80 0.05 5 0.45 0.40 0.43
2 80 0.05 10 0.52 0.47 0.50
3 80 0.05 15 0.57 0.55 0.56
4 80 0.10 5 0.82 0.62 0.72
5 80 0.10 10 1.02 0.92 0.97
6 80 0.10 15 1.14 0.95 1.05
7 80 0.15 5 0.54 0.55 0.55
8 80 0.15 10 0.60 0.80 0.70
9 80 0.15 15 0.74 0.90 0.82
10 150 0.05 5 0.41 0.36 0.39
11 150 0.05 10 0.58 0.42 0.50
12 150 0.05 15 0.62 0.58 0.60
13 150 0.10 5 0.77 0.80 0.79
14 150 0.10 10 0.87 0.91 0.89
15 150 0.10 15 1.15 0.95 1.05
16 150 0.15 5 0.79 0.75 0.77
17 150 0.15 10 1.06 1.07 1.07
18 150 0.15 15 1.27 1.37 1.32
19 220 0.05 5 0.25 0.26 0.26
20 220 0.05 10 0.45 0.46 0.46
21 220 0.05 15 1.31 1.49 1.40
22 220 0.10 5 0.62 0.55 0.59
23 220 0.10 10 1.09 0.86 0.98
24 220 0.10 15 1.33 1.42 1.38
25 220 0.15 5 0.91 0.85 0.88
26 220 0.15 10 1.35 1.26 1.31
27 220 0.15 15 1.46 1.49 1.48
Average 0.84 0.82 0.83
a
R
a

1
2
y
1
y
2
.
Table 7
ANOVA table for the K
s
Source of
variance
SDQ df
a
Variance F test F 5% P
(%)
b
A V
c
(m/min) 5578985.8 2 2789492.9 26.47 3.27 13.3
B f (mm/rev) 26156533.5 2 13078266.8 124.11 3.27 64.1
C t
c
(min) 2411201.5 2 1205600.8 11.44 3.27 5.4
AB 1166866.2 4 291716.6 2.77 2.64 1.8
AC 1004349.7 4 251087.4 2.38 2.64 1.4
BC 453151.1 4 113287.8 1.08 2.64 0.1
Error 3688068.9 35 105373.4 13.9
Total 40459156.7 53 100
a
Degrees of freedom.
b
Percentage of contribution.
Table 6
ANOVA table for the VC
Source of variance SDQ df
a
Variance F test F 5% P (%)
b
A V
c
(m/min) 1.082 2 0.541 137.7 3.27 57.4
B a (mm/rev) 0.058 2 0.029 7.3 3.27 2.7
C t
c
(min) 0.258 2 0.129 32.9 3.27 13.4
AB 0.141 4 0.035 9.0 2.64 6.7
AC 0.135 4 0.034 8.6 2.64 6.4
BC 0.061 4 0.015 3.9 2.64 2.4
Error 0.138 35 0.004 11.1
Total 1.872 53 100
a
Degrees of freedom.
b
Percentage of contribution.
Table 8
ANOVA table for the R
a
Source of variance SDQ df
a
Variance F test F 5% P (%)
b
A V
c
(m/min) 0.656 2 0.328 22.0 3.27 9.9
B f (mm/rev) 1.906 2 0.953 64.1 3.27 29.6
C t
c
(min) 2.053 2 1.026 69.0 3.27 32.0
AB 0.477 4 0.119 8.0 2.64 6.6
AC 0.648 4 0.162 10.9 2.64 9.3
BC 0.071 4 0.018 1.2 2.64 0.2
Error 0.521 35 0.015 12.5
Total 6.331 53 100
a
Degrees of freedom.
b
Percentage of contribution.
1190 J.P. Davim, L. Figueira / Materials and Design 28 (2007) 11861191
The specic cutting pressure is strongly inuenced by the
feed rate (64.1%).
The surface roughness is inuenced by feed rate (29.6%)
and cutting time (32%).
The use of ceramic tools with appropriate machining
parameters on hard turning of cold work tool steel per-
mit a surface roughness (R
a
< 0.8 lm) corresponding a
high dimensional precision (IT < 7 mechanic precision
construction) without necessity of cylindrical grinding
operations.
Acknowledgements
The authors acknowledge to the Mechanical Engineers
Paulo Matos and Miguel Faustino for their participation
on the experimental work.
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