Performance comparison of wiper and conventional ceramic inserts in hard turning of AISI 4140 steel: analysis of machining forces and flank wear

This paper describes a comparison of machining forces and flank wear between wiper ceramic (multi radii) and conventional ceramic cutting tools in dry hard turning of cold work tool steel AISI 4140 (60 Hardness Rockwell Cone (HRC)) using the Response Surface Methodology (RSM). For this purpose, a number of machining experiments based on statistical three-factor (cutting speed, feed rate, and depth of cut) and three-level factorial experiment designs completed with a statistical analysis of variance (ANOVA) were performed. From the parametric analysis, it is revealed that the uncoated ceramics (CC650WG wiper and CC650 conventional) performs better than the coated ceramics (CC6050WH wiper and CC650 conventional) with reference to machining forces. On the contrary, wiper ceramic cutting tools (CC6050WH and CC650WG) have the better performance compared with conventional ceramic cutting tools (CC6050 and CC650), in particular, the flank wear.