Comparison between mixed ceramic and reinforced ceramic tools in terms of cutting force components modelling and optimization when machining hardened steel AISI 4140 (60 HRC)

This paper describes a comparison between mixed ceramic [Al2O3 (70%) + TiC (30%)] and reinforced ceramic [Al2O3 (75%) + SiC (25%)] tools in terms of cutting force components when machining in dry hard turning AISI 4140 steel, hardened to 60 HRC. The response surface methodology (RSM) and the analysis of variance (ANOVA) are applied to investigate effects of cutting speed, feed rate and depth of cut on cutting force components in order to model and optimize these technological parameters. Results of this study indicate that the machining with the mixed ceramic insert generates lower values of cutting force components than reinforced ceramic insert. Consequently, the mixed ceramic CC650 is the most powerful tool. The developed models can be used in the metal machining industries and would be helpful in selecting cutting variables for optimization of hard cutting process