EXPERIMENTAL INVESTIGATIONS ON HARD

TURNING OF AISI52100 STEEL

PRESENTED BY
G. VENKANNA
G.PAVAN KUMAR
E.NAVEEN
B.REVAN KUMAR
B.SIDDHARTHA
UNDER THE GUIDENCE OF
P.UMA MAHESWARARAO
 OVERVIEW

Introduction to Hard turning

AISI 52100 steel
Importance of Hard turning
Selection of suitable tool
Requirements
Methodology
Expected outcomes
 INTRODUCTION TO HARD TURNING

HARD TURNING:

Hard turning means the process of cutting hardened pieces with in the 2
micron range using single point cutting tool with the hardness between 45
to 68 HRC. It is performed on a lathe or turning center.
HRC means Rockwell hardness measured on C scale.
AISI 52100 STEEL:

AISI means American Iron and Steel Institute

AISI 52100 STEEL which having the hardness greater than 45 HRC
They respond more quickly to mechanical and heat treatment than Carbon steels
When Heat treated Hardness of AISI 52100 Steel reaches up to 62 HRC
It is high Carbon, Chromium containing low alloy steels
It contains the following chemical composition
WHY HARD TURNING IS REQUIRED:

Hard Turning is applied to the manufacture of complex parts , manufacturing costs can
be reduced up to 30%
A qualitative comparison between hard turning and grinding process
 CUTTING TOOL MATERIALS FOR HARD TURNING :

The main tool materials that are used for Hard turning are:
Sintered carbides(hard metal):
CBN tool exhibits the best cutting performance in terms of both tool wear and surface finish and the highest volume of metal
removal is obtained.
Ceramics(Al2o3,si3n4 etc.)
Ceramics are very hard and refractory materials, with standing more then 1500 degree centigrade. when cutting speed increases tool
life increases
Extra Hard Materials like PCD,PCBN.
theses are ertra hard materials . Longest tool life is achieved.
The selection of appropriate tool material is vital for the process efficiency and depends on Accuracy and surface finish required .
Therefore selection of suitable tool material is one of the most important task in Hard turning
 METHODOLOGY

The work material is AISI52100 alloy steel which has its major application in bearings.
AISI52100 alloy steel is hardened by heating and followed by quenching.
The hardness after heat treatment is obtained as 58.00.5 HRC. The cutting inserts used are
PCBN tool inserts of different nose radius 0.4, 0.8, 1.2 mm.
Rigid, high power precision lathe equipped with specially designed experimental setup is used
for experimentation.
For increasing rigidity of machining system, work piece material is held between chuck (three
jaws) and tailstock (revolving center) and the turning of work piece in dry turning conditions
are conducted on centre lathe with variable speed & feed drive.
 Success in Hard Turning is defined by a number of factors:
Machine rigidity
Workholding Rigidity
Good vibration damping characteristics
Rigid tool location
Component part rigidity
Rigid cutting tools and advanced insert materials
 The cutting forces are measured using Kistler multi component dynamometer mounted on
specially designed fixture.
The outputs are tangential force (Fz), feed force (Fx) and thrust force (Fy) on the respective
charge amplifier generated and stored in computer using Lab VIEW software for further
analysis.
Based on tool manufacturer recommendations, feasible range of cutting parameters for a given
cutting toolwork piece system are selected as shown in the table 1.
 In the present work hard turning is carried out on AISI52100 steel using
PCBN cutting tool.
This study focuses on optimizing turning parameters based on Taguchi
method.
Influence of process parameters such as speed, feed, depth of cut and type of
tool inserts ANOVA(Analysis Of Variance).
 Literature review on effect of cutting parameters on surface roughness
B. Ravi Sankar, AISI 52100 Steel/PCBN Cutting speed (m/min): 400,
P.Umamaheswarrao 650, 900
(2017) [17] feed (mm/rev):0.04, 0.06,
0.08
Depth of cut (mm):0.4, 0.6,
0.8
Nose radius(mm): 0.4, 0.8,
1.2
Samir Khamel, AISI 52100 bearing steel/ with cutting speed (m/min): 100, 140,
Nouredine Ouelaa and CBN tool 200
Khaider Bouacha (2012) Feed rate (mm/rev): 0.08, 0.12,
[55] 0.16
Depth of cut (mm): 0.2, 0.4, 0.6
clearance angle (o): 6
rake angle (o): -6
cutting edge inclination
angle (o): -6
58 HRC ANOVA Results revealed that the force is Materials today proceedings/Elsevier
increasing with all the parameters;
however the increment is varying
with the individual parameters.
60 HRC ANOVA, RSM Cutting forces show an increasing trend Journal of Mechanical Science and
with the increase in feed rate and depth Technology/Springer
of cut on the other hand they show a
decreasing trend with cutting speed. The
depth of cut exhibits maximum influence
on cutting force components compared
to the feed rate and cutting speed.
Ajay Batish et al (2014) EN31 steels/CNGA
[58] 120404 AB 20 and
CNGA120408 AB 20
ceramic (Al2O3 + TiCN)
inserts
Gaurav Bartaryaa and AISI 52100 steel/ hone edge
S.K.Choudhury (2012) [60] uncoated CBN tool
Mohamed Walid Azizi et al AISI 52100 steel with coated
(2012) [47] Al2O3 + TiC mixed ceramic
cutting tools
Feed (mm/rev): 0.03
cutting speed (m/min): 75, 110,
150
Depth of cut (mm): 0.075, 0.15
nose radius (mm): 0.4, 0.8
Speed (m/min): 167, 204, 261
Feed (mm/rev): 0.075, 0.113, 0.15
Depth of cut (mm): 0.1, 0.15, 0.2
Cutting speed (m/min): 85, 120,
170
Feed rate (mm/rev): 0.08, 0.12,
0.16
Depth of cut (mm): 0.1, 0.2, 0.3
rake angle (o): -6
clearance angle (o): 6
cutting edge angle(o): 75
50, 55, 60 HRC ANOVA, GA Feed, speed, depth of cut-nose radius Journal of Mechanical Science and
and hardness had significant effect on Technology/Springer
machining force.
602 HRC ANOVA, RSM Depth of cut was found to be the most Procedia CIRP/ Elsevier
influential
parameter affecting the three cutting
forces followed by the feed.
46, 52, 56 and 62 ANOVA Depth of cut, work piece hardness and Journal of Mechanical Science and
HRC feed rate are observed to have a Technology/Springer
statistically significant impact on the
cutting force components than the cutting
speed.
Jeffrey D. Thiele, AISI 52100 steel / Cubic Cutting Speed
Shreyes N. Melkote boron nitride inserts (m/min):121.9
(1999) [49] Nose radius (mm): 0.81
Depth of Cut (mm): 0.254
Feed rate (mm/rev) : 0.05,
0.10, 0.15
Side rake angle(o): -5
Back rake angle(o): -5
Sudhansu Ranjan Das, AISI 52100 Steel/CBN tool cutting speed (m/min): 100,
Debabrata Dhupal and 140, 200
Amaresh Kumar Feed rate (mm/rev): 0.08, 0.12,
(2014) [54] 0.16
Depth of cut (mm): 0.2, 0.4,
0.6
rake angle (o): -6
clearance angle (o): 6
41, 47, 57 ANOVA Large edge hones of CBN tools Journal of Materials Processing
HRC result in higher forces in the Technology/ Elsevier
axial, radial, and
tangential directions as
compared to the tools with
small edge hone.
60 HRC ANOVA Depth of cut is the principal factor 5th International & 26th All India
affecting cutting force, followed by Manufacturing Technology, Design and
feed. Research Conference (AIMTDR 2014)
December 12th14th, 2014, IIT
Guwahati, Assam, India
I. Meddour et al (2015) AISI 52100 cutting speed (m/min): 100, 59 HRC RSM, ANOVA Depth of cut is the main International Journal of Advanced
[56] steel/ceramic tool 150, 200 parameter affecting the force Manufacturing
Depth of cut (mm): 0.05, components followed by feed Technology/Springer
0.15, 0.25 rate.
feed rate (mm/rev): 0.08,
0.11, 0.14
tool nose radius (mm): 0.8,
1.2, 1.6
cutting edge angle (o): 75
Clearance angle (o): 6
rake angle (o): 6
Cutting edge inclination
angle (o): 6.
 Literature review on effect of cutting parameters on surface roughness

Author/Year Work piece/ Tool Cutting parameters Work piece ModelingTech Remarks Journal/Publisher
material hardness

Chou, Y.K. AISI 52100/ Cutting speed (m/sec): 2-3 6062 HRC Not defined Large tool nose radii only give finer Journal of Materials Processing
Song, H. Alumina, Feed rate (mm/rev): 0.050.6 surface finish, but comparable tool wear Technology/Elsevier
(2004) [48] Titanium carbide Depth of cut (mm): 0.2 compared to small nose radius tools.
composite Nose radius (mm): 0.8, 1.6, 2.4
(70% Al2O3 and Flank Wear (mm): 00.2.
30% TiC) rake angle (o): 25
relief angle (o): 5

Suha K Shihab et al AISI 52100/ CNMG Cutting speed (m/min): 100, 175, 250 297.8 HV ANOVA The feed rate was found to Journal for Manufacturing Science and
(2014) [23] 120408-TN7105 coated Feed rate (mm/rev): 0.1, 0.16, 0.22 be the most influential factor for both the Production/DE GRUYTER
carbide insert Depth of cut (mm): 0.2, 0.6, 1 surface roughness and the micro
Nose radius (mm): 0.8 hardness.
L B Abhang and M En-31 steel cutting speed ( m/min): 39, 112, 189 - Mathematical model The surface roughness increases with Procedia Materials Science/Elsevier
Hameedullah Feed( mm/rev): 0.06, 0.1, 0.15 increase in feed rate followed by depth
(2014) [36] depth of cut (mm): 0.2, 0.4, 0.6 of cut but surface roughness decreases
with increase in cutting speed and tool
nose radius respectively.

Gaurav Bartaryaa and AISI 52100 steel/ hone Speed (m/min): 167, 204, 261 602 HRC ANOVA, RSM The surface roughness increased with Procedia CIRP/ Elsevier
S.K.Choudhury (2012) edge uncoated CBN tool Feed (mm/rev): 0.075, 0.113, 0.15 increase in depth of cut for most of the
[60] Depth of cut (mm): 0.1, 0.15, 0.2 feed values in range.

Samir Khamel, AISI 52100 bearing steel/ cutting speed (m/min): 100, 140, 200 60 HRC ANOVA, RSM Feed rate and cutting speed strongly influence Journal of Mechanical Science and
Nouredine Ouelaa and with CBN tool feed rate (mm/rev): 0.08, 0.12, 0.16 surface Technology/Springer
Khaider Bouacha (2012) Depth of cut (mm): 0.2, 0.4, 0.6 roughness.
[55] clearance angle (o): 6
rake angle (o): -6
cutting edge inclination
angle (o): -6
Salah R. Agha, C. Richard AISI 52100/BZN cutting speed (m/min): 106.7 62-63 Rc Not Defined choice of the cutting parameters Wear/ Elsevier
Liu (2000) [28] 8100 (by GE Feed rate (mm/rev): 0.051 greatly affects the surface
Super-abrasives) Depth of cut (mm): 0.254, integrity aspects
0.762 of the hard turned parts.
Round tool Diameter (cm):
1.27
Thickness (cm) 0.318
Lead angle (o): 90
clearance angle (o): 0

Singh, D. AISI 52100 / Cutting speed (m/min): 100, 150, 5802 HRC Response Better surface roughness at higher International Journal of Advanced
Rao, P.V. Mixed ceramic 200 Surface nose radius and at Manufacturing Technology/Springer
(2007) [20] inserts Feed (mm/rev): 0.10, 0.20, 0.32 Methodology. lower negative rake angle.
Effective rake angle (o): 6, 16, 26 ANOVA
Nose radius (mm): 0.4, 0.8, 1.2
Author/year Workpice Cutting parameters Work pice Modeling tech Remarks Journal/
/toolmaterials hardness Publisher

Sujit pawar AISI 5210 CUTTING 62HRC JOHNSON - Cutting speed increases then Materials today
Aniket slave STEEL/ SPEED(mm/min)75,100,125 COOK tensile residual strees are Elsevier
Ganesh lamdgade TH1000 FEED(mm/rev)0.15,0.2,0.25 increased when the feed and
(2017)2350-2359 DEPTH OF CUT(mm)0.4,0.5 depth of cut are fixed

P.s .Bhatt AIS52100STEEL/ CUTTING SPEED(mm/min)140,200,260 62HRC JOHNSON - Cutting speed increases then the Materials today
P.D.Dhikale PCBN CUTTING TEMPERATURE(oC)788,832,945.88 COOK friction between tool and workpice Elsevier
S.S.Chinchanikar TOOL also increses
Lei chen ,Bruce L.Thai, AIS52100STEEL/ FEED(mm/rev)0.05,0.1,0.15 62HRC TOOL FOIL The shear plane heat source was INTERNATIONAL
Rahul G.Chaudary PCBN CUTTING CUMULATIVE CUTTING TIME THERMO COUPLE demonstrated to be more JOURNAL OF MACHINE
TOOL (minits)4,12,24 METHOD significant than the flank face frictional heat TOOLS AND
source on peak machined surface
MATERIALS
temperature

Rajasekhar Lalbondrae, AISI52100 STEEL/ 400 rpm (123 m/min), 640 rpm (197 m/min) 60HRC TRADITIONAL TOOL life is within in permissible limits of5% PROCEDIA MATERIAL
Prasad Krisshna, CTLPR2020L16 and 800 rpm (246 m/min) LONITUDANAL CIENCE/ ELSEVIER
Mohan Kumar TURNUNG METHOD

Y.Kevin Chou AISI52100 STEEL / FEED(mm/rev)0.05,0.15.0.3,0.6 61HRC large MATERIALS PROCESING

Hui Song ALUMINA TOOL NOSE RADIUS(mm)0.8,1.6,2.4 tool nose radii only give finer surface TECHNOLOGY/ELSEVIER
TITATANIUM finish
CARBIDE
 APPLICATIONS

Dry cutting without coolant.

Manufacturing of Ball bearings, automotive, Gear and die industry.
EXPECTED OUTCOMES :

Influence of input parameters on the output response.

Correlating mathematical model between input and outputs.
Optimization of process parameters for efficient turning operation on AISI 52100 steel
THANK YOU