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Response Surface Modeling and Optimization of Cutting Temperature in Turning of AISI 52100 Hardened Alloy Steel under Minimal Cutting Fluid Application

The heat generation and subsequent temperature rise in the cutting zone due to plastic deformation and friction at tool-chip-workpiece interface are critical parameters that have a significant impact on tool wear, tool life and surface integrity. This paper aimed to analyse the effect of cutting parameters such as, cutting speed, feed and depth of cut on the cutting temperature in turning of hardened AISI 52100 alloy steel of 58 HRC using multilayer coated carbide cutting tool insert under high velocity pulsing jet minimal cutting fluid application (MCFA) environment. Response surface methodology based central composite design (CCD) was used to investigate and optimize the cutting parameters on cutting temperature response. The quadratic regression model in terms of cutting speed, feed and depth of cut for cutting temperature was developed. The diagnostic and confirmatory tests were carried out to check its validity. The implication of the process parameters and their interactions were tested using analysis of variance (ANOVA). The results showed that the cutting speed and feed were the main significant parameters affecting the cutting temperature, while depth of cut and quadratic term of cutting speed had a moderate effect. The predictive model developed indicates the 99% desirability level in turning of AISI 52100 hardened steel under the MCFA environment. The predicted values of cutting temperature response are in close agreement with the experimental results.