Analysis and optimisation of the cutting parameters based on machinability factors in turning AISI 4140 steel

Abstract

AISI 4140 alloy steel has high abrasion resistance, toughness, torsional, and fatigue strength. Different types of this alloy with different hardness are used to manufacture gears, crankshafts, collars, jigs, and milling spindles. In this study, turning tests were carried out on AISI 4140 steel using coated carbide inserts considering Taguchi L-9 orthogonal array at three different cutting speeds, feed rates, and cutting depths. The output parameters were selected as cutting forces, surface roughness, current and sound intensity. According to the ANOVA results, feed rate was the most effective parameter on the cutting force and surface roughness. As the feed rate increases, the cutting force and surface roughness value enhance. The feed rate was also the most important factor affecting the current with 81.61% contribution, followed by cutting depth with 12.67% contribution. The cutting depth with 66.95% contribution has the highest impact on the sound intensity. It was followed by a feed rate with 26.07% contribution. According to the optimisation results, the experimental and the estimated values were significantly close to each other.