Effect of Cutting Parameters on Cutting Forces and MRR During Turning Hard Alloy Steel With and Without Coolant

This paper investigates the effect of different cutting parameters (cutting speed, feed rate, and depth of cut) on cutting force components and material removal rate (MRR) in dry and wet hard turning processes. The workpiece material, hardened alloy steel AISI 52100, was machined on a CNC lathe with coated carbide tool under different settings of cutting parameters. Three cutting parameters each at three levels were considered in the study. Central composite design (CCD) of experiment was used to collect experimental data for cutting force components and MRR. The results were analyzed using an effective procedure of response surface methodology (RSM) to determine optimal values of cutting parameters. Statistical analysis of variance (ANOVA) was performed to determine significance of the cutting parameters. Several diagnostic tests were also performed to check the validity of assumptions. The results indicate that cutting force components are influenced principally by the depth of cut, while the effect of both cutting speed and feed rate is small. On the other hand, the depth of cut has the most significant effect on the MRR; the cutting speed has less significant effect whereas feed rate has the lowest effect. Finally, the ranges for best cutting parameters and model equations to predict the cutting force components and MRR are proposed.