Optimization of Cutting parameters when Hard Turning Hardened 42CrMo4 steel using the Taguchi Method

The general objective of this research study was to advance a science-based predictable understanding of a polycrystalline cubic boron nitride (PCBN) tool during hard turning of chromium - molybdenum alloy steel (42CrMo4) and establish optimal machining parameters to enhance tool performance. Three different cutting speeds namely 105, 140 and 170 m/min with three different feed rates (0.15, 0.2 and 0.3 mm/rev) at a constant depth of cut (0.5 mm) were used to carry out the experiments. The Taguchi method, statistical methods of signal to noise ratio (SNR) and the analysis of variance (ANOVA) were applied to investigate the effects of cutting speed and feed rate on Tool life, surface roughness, cutting force and tool wear. From the ANOVA analysis it was concluded that the effect of feed rate had more influence than cutting speed, which entails that for improved tool life, slower cutting speeds should generally be selected in combination with suitable feed rates.