SINERGI Vol.
No.
June 2019: 139-144 Accredited SINTA 2 by KEMENRISTEKDIKTI.
Decree No: 10/E/KPT/2019 http://publikasi.
id/index.
php/sinergi http://doi.
org/10.
22441/sinergi.
VARIATION OF CUTTING PARAMETERS IN THE PROCESS OF
TURNING AISI 4340 STEEL ON SURFACE ROUGHNESS
Sobron Y.
Lubis.
Erwin Siahaan.
Steven Darmawan.
Adianto.
Ronald Department of Mechanical Engineering.
Faculty of Engineering.
Universitas Tarumanagara Jl.
Let.
Jend.
Parman.
No.
1 Jakarta 11440.
Indonesia Email: sobronl@ft.
id erwins@ft.
id stevend@ft.
adianto@ft.
id RonaldRaffli@gmail.
Abstract -- In the metal machining process, cutting speed and feed rate are cutting parameters that affect the surface quality of the workpiece produced.
The use of improper cutting parameters can cause the workpiece surface to be rough, and the cutting toolage to be shorter.
This study was conducted to determine the effect of cutting parameters and the use of carbide tools on the surface roughness of metal steel workpieces.
The research was carried out using the experimental method of AISI 4340 steel metal workpiece turning using cutting tool coated.
Five variations of cutting speed used are: 140 m/min, 150 m/min, 160 m/min, 170 m/min, 180 m/min and three variations in feed rate: 0.
25 mm/rev, 0.
mm/rev, 0.
35 mm/rev.
After the turning process, the surface roughness of the workpiece is measured using a surface tester.
From the results of the study, it was found that the surface roughness value was directly proportional to the feed rate and inversely proportional to the cutting speed.
The smallest surface roughness value is 9.
56 m on cutting speed 180 m / min, and feed rate is 0.
25 mm/rev.
Keywords: Machining process.
Cutting parameter.
Cutting speed.
Feed rate Copyright A 2019 Universitas Mercu Buana.
All right reserved.
Received: August 14, 2018
INTRODUCTION
In the metal machining process, the quality of the product depends on the parameters and cutting tool that be used.
Generally, machining parameters that determine on machining process is feed rate that means feeding speed by cutting machine, and cutting speed (Yang et al.
, 2019.
Tuysuz & Altintas, 2.
The research carried out by Handoko & Mudjijana .
on optimization parameters for machining of Ductile Iron Materials, states that the cutting parameter optimization is determined by the ratio of the parameter comparison to obtaining the optimization parameters (Mikoleizig, 2.
Hard turning operations involve the cutting of materials with hardness ranging from 58 to 68 Rockwell C (HRC) (Ferreira et al.
, 2.
AISI 4340 medium carbon .
4% C) high strength martensitic steel is one such desirable material used very frequently to manufacture critical components in aerospace engineering and manufacture of bearings, gears, shafts, and cams, which require higher geometric tolerances, longer service life, and excellent surface finish (Rashid et , 2.
Many aerospace and automotive systems require structural parts presenting high in-service performance.
Gears and crankshafts are among these components, whose surface Revised: April 3, 2019 Accepted: April 6, 2019 (Jomaa et al.
, 2.
and subsurface characteristics play a crucial role in controlling their service life.
The major problem during hard turning is the high heat generation due to friction between a chips-tool interface that causes a higher wear rate, low surface quality, and shorter tool lives.
Therefore, tool life and surface quality of the components can be improved by controlling the temperature of the cutting zone (Kumar et al.
In its current state, hard turning differs from conventional turning on account of several factors including the cutting tool, workpiece, or the process itself, all of which may influence the machining outcome (Agrawal et al.
, 2.
Using various cutting parameters is done to determine the surface of the workpiece made and also to determine the age of the cutting tool.
course, in the machining process, right surface conditions are desired.
Good surface conditions are determined based on the surface roughness produced according to the plan.
Learning the proper cutting speed can provide a good workpiece surface.
In general, the value of cutting speed and feed can be obtained through the table presented by Kalpakjian & Schmid .
But recommendations for the use of cutting parameters that are effective in reducing each Lubis et al.
Variation of Cutting Parameters in The Process of Turning Aisi 4340 A SINERGI Vol.
No.
June 2019: 139-144 However, no information on the use of cutting speeds that results in an excellent surface roughness value is obtained.
Therefore, it is necessary to conduct a scientific study on the use of various cutting parameters in the AISI 4340 steel turning process using carbide cutting tools to determine the surface conditions of the resulting workpiece AISI 4340 .
edium carbon .
4 % C)
8 % nickelAechromiumAemolybdenu.
is a high strength martensitic steel.
It is generally supplied hardened and tempered in the tensile range of 0.
9 to 1 GPa, but further improvement in the mechanical properties beyond pre hardening and tempering is possible through surface hardening by flame or induction hardening and by It is used for manufacturing critical automotive transmissions .
, manufacturing of bearings, gears, heavy-duty shafts, axles, spindles, couplings.
Pins, and cams which require tighter geometric tolerances, longer service life and excellent surface finis.
, and metal forming moulds where severe dynamic load imposes strict conditions on surface quality (Rashid et al.
, 2.
MATERIAL AND METHOD
Material Experimental process of AISI 4340 steel turning using Mazak CNC lathes.
Evaluated the performance of coated cemented carbide inserts during machining of hardened AISI 4340 steel.
The analysis of results concluded that low feed rate, little depth of cut, and high cutting speed were beneficial for minimizing the cutting force.
However, lower cutting speed and feed values were useful for reducing (Pal et al.
, 2.
AISI 4340 alloy steel is selected as the workpiece material.
It is being used in manufacturing industries where high tensile and yield strength are required.
Components made of AISI 4340 steel are widely used in aircraft, automotive and general engineering industries, rotor shaft, propeller shafts, connecting rods, gear shafts, and other automobile parts (Kumar et , 2.
The tool wears the cutting tool used is a TNMG carbide coated type.
Fig.
1 shows a carbide The chemical composition, the properties of materials, and the dimension of AISI 4340 Steel are shown in Fig.
Figure 1.
Carbide Coated Chemical Composition of AISI 4340 Steel Element Iron.
Fe Nickel.
Ni Chromium.
Cr Manganese.
Mn Carbon.
C Molybdenum.
Mo Silicon.
Si Sulfur.
S Phosphorous Content (%) Properties of Material Properties Tensile strength Yield strength Bulk modulus .
ypical for stee.
Shear modulus .
ypical for stee.
Elastic modulus Poisson's ratio Elongation at break Reduction of area Hardness.
Brinell Metric 745 MPa 470 MPa 140 GPa 80 GPa 190-210 GPa Figure 2.
AISI 4340 Steel AISI 4340 steel is a difficult to machine material because of its high hardness, low specific heat and tendency to get strain hardened.
It is known for its toughness and capability of developing high strength in the heat-treated condition while retaining good fatigue strength.
Machining is best done with this alloy in the annealed or normalized and tempered condition.
Lubis et al.
Variation of Cutting Parameters in The Process of Turning Aisi 4340 A p-ISSN: 1410-2331 e-ISSN: 2460-1217 AISI 4340 has good ductility in the annealed condition, and most forming operations are carried out in that condition.
It can be bent or formed by spinning or pressing in the annealed state.
AISI
4340 is high tensile strength general engineering steel ideal for automotive and aircraft Axles & axle components, arbors, extrusion liners, lines extrusion, magneto drive coupling, shaft & wheels, pinions & pinion shafts are the application range of AISI 4340 alloy steel.
AISI 4340 is a more robust and more ductile material than EN-19 due to the Ni and Chrome alloying additions (Das et al.
, 2.
Measurement of the surface roughness of the workpiece using a surface tester Mitutoyo type A surface tester Mitutoyo type 211 is shown in Fig.
The mechanism of the cutting process in CNC Turning is depicted in Fig.
Figure 3.
Surface Tester Mitutoyo 211 Figure 4.
Mechanism of Cutting Process in CNC Turning.
Chuck, 2.
Tool holder 3.
Cutting tool insert, 4.
Workpiece 5.
Cutting motio.
Method This research was carried out by an experimental approach.
the experiment was carried out with variations in cutting speed and cutting conductivity.
The workpiece is gripped on the lathe chuck.
the carbide insert cutting tool is attached to the tool holder and attached to the Cutting speed and cutting conductivity are determined on the machine.
The cutting tool is then moved close to the surface of the workpiece.
The spindle rotates, and the cutting tool moves towards the workpiece surface to carry out the cutting process.
The Cutting process is carried out so that it reaches the specified cutting length limit.
Then the machine is stopped, then the surface roughness tester is placed above the surface of the workpiece then the observation and surface roughness of the workpiece is carried out.
The surface roughness of any material during turning depends on cutting speed, feed rate, depth of cut, and approach angle (Kumar & Chauhan, 2.
All output parameter always show the linear relation with a depth of cut.
In this machining process is done without using coolant.
The value of the surface roughness obtained is then inserted into the table to be further made into the graph and After taking the data of surface roughness values, the turning process is carried out again by changing the combination of cutting speed and cutting conductivity that has been Lubis et al.
Variation of Cutting Parameters in The Process of Turning Aisi 4340 A SINERGI Vol.
No.
June 2019: 139-144 The cutting speed and feed rate are the essential machining parameters on the surface At low cutting speeds .
m/mi.
there is a large quantity flow of material on the cutting edge that caused the large surface roughness due to high friction.
At high cutting speeds .
m/mi.
, it is monitored that the matrix material deformed to a lesser extent causing the surface roughness is reduced to 0.
48m (Kumar & Chauhan, 2.
After every turning operation, specimens were cleaned, and surface roughness was measured with a suitable clamping arrangement.
The surface roughness was measured at three points on the specimen and average of that measurements was taken as the final roughness value (DAoAddona & Raykar, 2.
The surface roughness value for the gear surface quality standard is 1.
04 m (Handoko & Mudjijana, 2.
, as shown in Fig.
Figure 5.
Surface Roughness Measurement RESULTS AND DISCUSSION The surface roughness values obtained in each machining parameter used are listed in Table 1.
Table 1.
Surface Roughness AISI 4340 Steel Surface roughness (R.
(AA.
Vc1
Vc2
Vc3
Vc4
Vc5
10,04
9,986
9,746
9,562
8,848
18,538
17,60
17,29
17,14
16,97
26,67
26,10
25,43
25,41
Ra (AA.
Cutting Where:
Vc1 is 140 m/min.
Vc2 is 150 m/min.
Vc3 is 160 m/min.
Vc4 is 170 m/min Vc5 is 180 m/min F1 is 0.
25 mm/rev.
F2 is 0.
30 mm/rev.
F3 is 0.
35 mm/rev The effect of cutting speed on the value of surface roughness of the workpiece resulting from cutting can be seen in Fig.
The effect of cutting feed on the value of the surface roughness of the workpiece resulting from cutting can be seen in Fig.
140 m/min 150 m/min 160 m/min 170 m/min 180 m/min 0,25 0,35 Feed Rate .
m/re.
Figure 6.
Graphic Feed Rate Vs.
Surface Roughness Source Lubis et al.
Variation of Cutting Parameters in The Process of Turning Aisi 4340 A p-ISSN: 1410-2331 e-ISSN: 2460-1217
12,856
Ra (AA.
9,54 6,872 12,354 9,124 6,684 12,166 11,644 11,604 8,432 8,056
6,512
6,352
7,874
6,306
0,25 mm/rev 0,3 mm/rev 0,35 mm/rev Vc .
/mi.
Figure 7.
Graphic Cutting Speed Vs.
Surface Roughness Feed Rate Effect on Surface Roughness In Fig.
6 can also be seen that the increase in the feed rate value affects changes in the amount of the surface roughness of the workpiece, the value of the surface roughness of the workpiece is higher.
This phenomenon is happening because the feed rate is a cutting motion that causes the cutting tool's tip to move to the surface of the workpiece, which scratches the surface of the material with cutting speed.
The smaller the feed rate value is used, the feeding speed becomes slower, which results in a tighter all parts of the workpiece surface uniformly.
However, if the feed rate is high, swipe that occurs per rotation faster so that it does not touch the entire surface of the workpiece in one rotation.
This case causes an uneven surface to appear and has a higher surface of the workpiece.
Cutting Speed Effect on Surface Roughness Based on observations made, obtained the value of cutting speed affects the results of the quality of the workpiece surface.
There are differences in the results of the surface roughness level on variations in cutting speed.
The higher the cutting speed used, the smaller the surface roughness value in other words, the better the surface quality of the workpiece.
High cutting speed results in a decrease in the cross-sectional area of the sliding city.
When the spindle rotation is high, the cutting speed is also high, and the cutting tool moves quickly to scratch the workpiece This process results in a narrower crosectional area resulting in narrowing of the crosectional area resulting in better surface quality.
circumstances are also seen that the variation in cutting speed changes in surface quality.
The use of cutting speed variations results in differences in the level of surface roughness The lowest surface roughness was obtained at the highest cutting speed of 180 m / min, and the most economical feed rate was 0.
mm/rev.
The use of low cutting speed and a high feed rate results in larger surface roughness The condition of cutting speed variation has limitations, meaning that the higher the cutting speed used, it can lead to narrowing of the crosection area.
The reduction of the cross-sectional area affects the surface quality CONCLUSION The conclusions obtained from the experiment and data analysis are as follows.
value is directly proportional with feed rate, while inversely proportional with cutting speed (V.
Then, to get a low surface roughness value or smooth need a high cutting speed and flat feed Cutting tool coated also has a resilience when doing a machining process without coolant.
The smallest surface roughness value is 9.
56 AAm on cutting speed 170 m/min, and the feed rate is 25 mm/rev.
REFERENCES