Investigating the Machinability of AISI 420 Stainless Steel Using Factorial Design

Abstract

This work aims at studying the machining characteristics of high-strength materials using carbide cutting tool inserts at different cutting conditions. This is an essential step in building up an accurate machining information system. The tested material is high-strength stainless steel of the AISI 420 type. Machining tests were carried out using orthogonal cutting conducted to investigate the machining characteristics for high-strength stainless steel AISI 420 at different cutting conditions and tool rake angles. This assessment is achieved by investigating the effect of cutting parameters (cutting speed, feed, depth of cut, and tool geometry) on cutting forces, specific cutting energy, shear angle, coefficient of friction, shear stress, shear strain, and shear strain rate. Empirical equations and a correlation for the behavior of each of the output responses were investigated as a function of the independent variables. Main effect and interaction plot were presented for the most influential factors affecting the main cutting force and the power consumed.

Keywords:

• Coefficient of friction
• Correlation
• Cutting forces
• Interactions
• Machining
• Main effects
• Metal cutting
• Power consumed
• Regression analysis
• Shear angle
• Shear strain
• Shear strain rate
• Shear stress
• Specific cutting energy
• Stainless steel

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Erratum

ACKNOWLEDGMENTS

The author would like to thank Princess Fatimah Alnajras's Research Chair of Advanced Manufacturing Technology for supporting this research.