Predictive Modeling of Cutting Forces and Tool Wear in Hard Turning using Response Surface Methodology

In the present study, an attempt has been made to investigate the effect of cutting parameters on cutting forces and tool wear in hard turning of AISI H13 tool steel using ceramic tool. The machining experiments were performed in accordance to Central Composite Design (CCD). The second order regression model of machining forces and tool wear has been developed. The influence of each operating factors have been studied through analysis of variance (ANOVA) technique. The obtained results reveal that, cutting speed and depth of cut have significant effect on feed force whereas feed rate and depth of cut are factors that significantly influences on thrust force. The depth of cut and cutting speed has predominant effect on tool wear. Feed rate have less significant effect on tool wear. But, in case of cutting force modeling, all the three parameters have significant effect. Key parameters and their effects on tool wear and cutting forces have also been presented in graphical contours which may help for choosing operating parameter preciously. Optimized model indicates desirability level for economy in hard turning process.