Effect of Machining Parameters on Tool Wear in Hard Turning of AISI D3 Steel

Present day metal cutting industry has to meet the challenges of quality and productivity of the machined parts during turning economically. In the present work, an attempt has been made to develop a model and predict tool flank wear of hard turned AISI D3 hardened steel using Response Surface Methodology (RSM). The combined effects of cutting speed, feed rate and depth of cut are investigated using contour plots and surface plots. RSM based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic tool with corner radius 0.8 mm is employed to accomplish 20 tests with six centre points. The adequacy of the developed models is checked using Analysis of Variance (ANOVA). Main and interaction plots are drawn to study the effect of process parameters on output responses.