Effect on Surface Roughness and Tool Wear during Turning of AISI 1020 Steel using Coated Carbide Inserts

The prediction of tool wear and surface roughness before machining has become an important task for the industry to be able to control and optimise the machining parameters effectively. In this paper the average surface temperature of the work-piece is obtained from the simulation model developed using DEFORM software. The work-piece used was AISI 1020 STEEL and the coated carbide tool insert was CNMG 432 TT 5100. The simulation model was validated by measuring temperature while machining. The surface roughness of the work-piece is then predicted using this DEFORM temperature as a parameter along with cutting speed, feed and depth of cut by using RSM Methodology. The experimental values and predicted values of surface roughness, tool wear comply with in the permissible interval. Optimisation of the values is done using Integrated PCA-Taguchi method. Results showed that surface roughness, tool wear were influenced the most by feed rate. Therefore the simulation model developed can be used for accurately forecasting the surface roughness for a given set of parameters.