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Materials Today: Proceedings 5 (2018) 6560–6569 www.materialstoday.com/proceedings

IMME17

Hard turning of AISI 4340 steel using coated carbide insert: Surface
roughness, tool wear, chip morphology and cost estimation
Sudhansu Ranjan Dasa,*, Asutosh Pandab, Debabrata Dhupalb
a
Department of Mechanical Engineering, JK Lakshmipat University, Jaipur, 302026, India
b
Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, 768018, India

Abstract

The present study addresses surface roughness, flank wear and chip morphology during dry hard turning of AISI 4340 steel (49
HRC) using CVD (TiN/TiCN/Al2O3/TiN) multilayer coated carbide tool. Three factors (cutting speed, feed and depth of cut) and
three-level factorial experiment designs with Taguchi’s L9 OA and statistical analysis of variance were performed in order to
investigate the effect of these cutting parameters on the tool and workpiece in terms of flank wear and surface roughness. The
results shows that surface roughness and flank wear are statistically significant influenced by feed and cutting speed. In fact,
increase in cutting speed resulted in better surface finish as well as increase in flank wear. For better understanding of the cutting
process, surface topography of machined workpieces, wear mechanisms of worn coated carbide tool and chip morphology of
generated chips are observed by scanning electron microscope (SEM). Consequently, MRA was adopted to develop
mathematical model for each response, along with various diagnostic tests were performed to check the validity and efficacy of
the proposed model. Finally, to justify the economical feasibility of coated carbide tool in hard turning application, a cost
analysis was performed based on Gilbert’s approach by evaluating the tool life under optimized cutting condition (suggested by
response optimization technique) and estimated that the total machining cost per part is Rs.8.21 for machining of hardened AISI
4340 steel with coated carbide tool.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and
Manufacturing Engineering (IMME17).

Keywords: Hard turning, surface roughness, flank wear, chip morphology, ANOVA, cost analysis.

* Corresponding author. Tel.: +91-9937347205.

E-mail address: das.sudhansu83@gmail.com

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering
(IMME17).
 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569 6561

1. Introduction

Now-a-days due to growing demand of high precision components to attain peak performances, hardened steels
with hardness above 45HRC have numerous applications in automotive gear, machine tool and die industry because
of their superior characteristics. In hard turning, high hardness of workpiece materials, significant cutting forces and
elavated temperatures at the workpiece-cutting tool interface indicate strict necessity for tool wear resistance and
tool rigidity. Normally these conditions give rise to the damage of the interact surfaces (tool-chip and workpiece-
tool); as a reaction, the geometrical and dimensional precision are decreased or altered and more the material
mechanical properties are changed [1]. Therefore not only force and temperature distribution in the cutting zone are
of great importance, but the study of surface roughness, tool wear and chip formation are also required for the
betterment of productivity, the improvement of quality of the machined products and the establishment of a techno-
economical and environmental friendly machining process.
The paper by Aslan et al. [2] (i) employed L27 Orthogonal array (OA) for planning of experimental design; (ii)
used ANOVA to evaluate the significance of cutting parameters on surface roughness and flank wear; (iii) applied
S/N ratio of Taguchi method to obtain the best combination of cutting parameters for optimization of surface
roughness and flank wear; and (iv) utilized multiple regression analysis to predict Ra and VB as functions cutting
speed v, feed f, depth of cut d. The outcomes of their analysis revealed that VB value decreases and afterwards
increases with feed, whereas surface roughness Ra decreases with an elevated cutting speed but impairs with feed.
Sahoo and Sahoo [3] investigated the performance of TiN/TiCN/Al2O3/TiN multilayer CVD coated carbide insert by
considering the effect of cutting parameters (v, f, d) in finish hard turning of AISI 4340 steel. The mathematical
modeling and parametric optimization on tool flank wear and surface roughness were presented by approaching
RSM and grey-based-Taguchi method. Additionally, their results highlight the cost estimation based on total
machining cost per part to vindicate the economic viability of coated carbide tool in hard turning process. During
machining of hardened AISI D3 steel with coated carbide tool, the RSM and Taguchi methods were utilized for the
optimization of surface roughness and tool wear by Dureja et al. [4]. They analyzed the results of an observation
regarding the effect of cutting speed, feed and depth of cut on surface roughness and flank wear. According to
parametric analysis ANOVA, feed and cutting speed were the significant factors influencing flank wear and the
factor significantly affecting surface roughness is feed. Das et al. [5] performed hard turning experiments on AISI
4140 steel (52 HRC) with TiN coated Al2O3 +TiCN mixed ceramic insert using full factorial design (FFD) for
surface roughness and flank wear. The outcomes of this investigation reveal that, feed followed by cutting speed and
cutting speed-depth of cut significantly affected surface roughness; whereas cutting speed had the largest influence
on flank wear. Aouici et al. [6] have applied ANOVA and RSM to examine the effects of machining parameters
including cutting speed, feed and machining time for modeling and optimization of surface roughness and flank
wear in hard turning of AISI H11 (X38CrMoV5-1) steel with CBN tool. Conclusions showed that flank wear is
predominantly controlled by machining time followed by cutting speed, while feed in case of surface roughness. In
finish dry hard turning of AISI D2 steel, Gaitonde et al. [7] studied surface roughness and tool wear to investigate
the performance comparison of conventional and wiper ceramic inserts. They published that better surface finish and
reduced tool wear are achieved with wiper geometry. Tool wear is highly sensitive to cutting speed and feed; on the
other hand, feed has predominant effect on surface roughness. In turning hot work tool steel AISI H11 with ceramic
tools, Saini et al. [8] presented that surface roughness is vitally affected by feed and nose radius, serving as when
feed inflates surface roughness maximizes but subsides with increase in nose radius. Apart, tool wear becomes
predominant when cutting speed increases succeeded by nose radius. In another study, acknowledged by Dureja et
al. [9] that surface roughness significantly revamps using machining parameters such as feed, workpiece hardness
and cutting speed while flank wear is realized under the effect of cutting speed and feed which are found the most
significant during finish turning of hardened AISI H11 steel with CBN tools.
Most of the literatures have focused on assessment, modelling and optimization for surface roughness and tool
wear but almost no or little research work has been yet reported on machined surface morphology, mechanism of
tool wear, chip morphology and economical feasibility which needs to be considered for to improve the overall
productivity in manufacturing by hard turning operation from technological, ecological and economical point of
views. Therefore, the current experimental work is to investigate the influence of cutting parameters (cutting speed,
6562 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569

feed and depth of cut) on surface roughness and flank wear by using combined techniques like Orthogonal array
(OA) of Taguchi technique and statistical ANOVA associated with main effect plots in finish turning of AISI 4340
steel (hardened to 49 HRC) with multilayer (TiN/TiCN/Al2O3/TiN) coated carbide insert. Additionally, surface
topography of machined workpiece, wear mechanisms of worn coated carbide tool and chip morphology of
generated chips are investigated using scanning electron microscope (SEM).

2. Experimental procedure

To acquiesce the purpose of research work, cutting speed (v), feed (f) and depth of cut (d) have been chosen as
cutting parameters, while the responses are surface roughness, flank wear and chip morphology. The identified
factors and their associated levels are presented in Table 1. Using the selected factors (three) and factor levels
(three), a design matrix was formulated in conformance with L9 (33) Taguchi’s Orthogonal array design. The
experimental design matrix and results are showed in Table 2.

Table 1. Factors and levels

Factors Unit Levels
1 2 3
Cutting speed (v) m/min 100 160 220
Feed (f) mm/rev 0.05 0.09 0.13
Depth of cut (d) mm 0.20 0.40 0.60

Table 2. Taguchi’s orthogonal array L9 experimental design and results

Run Coded values Actual setting Experimental results
v f d v (m/min) f (mm/rev) d (mm) Surface roughness, Ra (µm) Flank wear, VB (mm)
1 1 1 1 100 0.05 0.2 0.994 0.05
2 1 2 2 100 0.09 0.4 0.633 0.073
3 1 3 3 100 0.13 0.6 0.916 0.105
4 2 1 2 160 0.05 0.4 0.836 0.095
5 2 2 3 160 0.09 0.6 0.574 0.124
6 2 3 1 160 0.13 0.2 0.883 0.145
7 3 1 3 220 0.05 0.6 0.698 0.185
8 3 2 1 220 0.09 0.2 0.566 0.167
9 3 3 2 220 0.13 0.4 0.776 0.225

Dry longitudinal turning of round bar (80 mm diameter and 100 mm length) of AISI 4340 high strength low alloy
steel (HSLA) was performed using CNC lathe (model: SPRINT 16TC, make: Batliboi Ltd.) with 7.5 kW at
maximum spindle power. The elemental composition of the workpiece material determined by spectro metal
analyzer is displayed in the Table 3. Before conducting experimental runs, the workpiece material was applied to
heat treatment (quenching at 9200C and tempering at 4000C) to obtain an average hardness of 49 HRC, followed by
removal of burr, oxide layers and other defaults from the exterior surface of the specimen. The cutting tool was used
CVD multilayer (TiN/TiCN/Al2O3/TiN) coated carbide inserts (make: Taegutec Ltd.) having ISO designation
CNMG120408 TT9235 were mounted on a tool holder PCLNL2525 M12 (Ceratizit make), which derives a back
rake angle -60, approach angle 950, including angle 800, clearance angle 60 and nose radius of 0.8 mm. Surface
roughness (Ra) was recorded using Surftest SJ-210 Mitotoyo roughness tester during each experiment. The
measurement of tool wear (here, flank wear VB) was done by optical microscope fitted with a digital camera and
image analysis software. The measurement of chip thickness and the observation of chip shape are accomplished by
collecting chip samples during experimental tests followed by measuring the average chip thickness with fifteen
 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569 6563

samples using digital vernier caliper. For extensive understanding of the cutting process, the quality of the hard
turned surface, wear mechanisms of the worn cutting insert and chip morphology were observed by scanning
electron microscope (model: EVO MA15, make: Carl Ziess SMT, Germany). The schematic layout of the
methodology followed in this study, is presented in Fig. 1.

Table 3. Chemical composition of AISI 4340 steel (wt%)

C Mn Si S P Ni Cr Mo Fe
0.384 0.613 0.231 0.028 0.025 1.418 1.007 0.230 Balance

Machined work surface

temperature measurement
Cutting parameters
Hard turning
operation
Chuck

Cutting insert
Workpiece (AISI 4340)

Machined
workpiece
Flank wear
measurement
Surface roughness Cutting chips
measurement

Chip thickness
SEM observation measurement

Machined surface Worn tool Chip morphology

Main effect plots

Conclusion

Fig. 1. Schematic layout of methodology proposed

6564 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569

3. Results and discussion

3.1. Analysis of Surface roughness

Analysis of the experimental results for surface roughness obtained through Taguchi’s OA experimental design,
are carried out with statistical ANOVA for evaluating the factor significantly influencing surface roughness (Ra) is
presented in Table 4. Out of the parameters taken into account the effect of feed (F= 42.81) is most significant on the
output response surface roughness (Ra), followed by cutting speed (F= 13.37), as its F calculated value is more than
F-table value (9.0) and probability (P) value is less than 0.1 with 90% confidence level. The feed and cutting speed
factors affect the surface roughness by 70.22% and 21.93% respectively. Although depth of cut does not present an
important effect (insignificant), accounting 6.21% of total variability but it has decreasing control on Ra.

Table 4. ANOVA for surface roughness (Ra)

Source DOF Seq. SS Adj. SS Adj. MS F P-value C (%)
v 2 0.042169 0.042169 0.021084 13.37 0.070 21.93
f 2 0.135049 0.135049 0.067524 42.81 0.023 70.22
d 2 0.011942 0.011942 0.005971 3.79 0.209 6.21
Error 2 0.003155 0.003155 0.001577 1.64
Total 8 0.192314 100
S= 0.0397157 R-Sq= 98.36% R-Sq(adj)= 93.44%

The main effect plot in Fig. 2 indicates that, the surface finish is eloquently improved by increasing cutting
speed. This is for the reason that with rise in cutting speed, the frictional energy and shear plane energy are optimal
[10] followed by culminated temperature at the shear plane and machined workpiece surface (see, Fig. 3), along
with enhances the thermal softening of workpiece material and hence, forces needed for cutting decreases that
causes an improved surface finish. Another way; this decrease of surface roughness can be described by the reduced
built-up-edge (BUE) formation, because of excess temperature produced in the chip-tool interface area as a function
of raised cutting speed. When the built-up-edge becomes unstable and large, it results improved surface finish. This
study is analogous to the results obtained during turning of hardened AISI 52100 steel with CBN tool [11]. The
typical trend of curve in Fig. 2 represents gradual increase in feed enables surface roughness (Ra) diminish prior to
lowest value is achieved beyond which Ra again upsurges. With feed upto 0.09 mm/rev, surface finish improves due
to fact that the uncut chip thickness becomes very small which might give rise to the ploughing (led to material side
flow), instead cutting of material at lower feeds relative to higher feeds, as reported by Rech and Moison [12] and
Bartarya and Choudhury [13]. Nevertheless, more increase in feed, the contact length between the w/p and the tool
increases [14,15] and hence resulting in high thrust force [16] since the cutting tool has to extract more volume of
material from the workpiece [17,18] thereby more vibration and heat generation [19] resulting in high Ra values.
Fig. 4(a) and (b) displays the SEM images of the poor and best surface texture quality attained by the interaction
between AISI 4340 hardened steel and multilayer (TiN/TiCN/Al2O3/TiN) coated carbide tool using various cutting
conditions. From experimental observation, test number 1 (v= 100 m/min, f= 0.05 mm/rev and d= 0.2 mm) and test
number 8 (v= 220 m/min, f= 0.09 mm/rev and d= 0.2 mm) support the evidence of these (poor and best) surface
development. The SEM images show the status of machined surface in terms of surface voids, adhered oxides and
chip particles, feed marks, material side flow, un-machined material, rough and smooth surface. The better surface
finish due to increased cutting speed clearly noticed in Fig. 4. In Fig. 4(a), at lower feed (0.05 mm/rev) feed marks
become less apparent compared to a higher feed of 0.09 mm/rev (see, Fig. 4(b)). For all turning tests, the measured
Ra values were in the range of 0.566 - 0.994 μm, showing that coated carbide tool is effective to produce
components with surface corresponding to those obtaining from grinding and other finishing operations.
 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569 6565

Ra T
0.82 90

88

Machined surface temperature ( C)

0.81

0
86

Surface roughness (µm)

0.80
84

0.79
82

0.78 80

78
0.77

76
0.76
74
100 120 140 160 180 200 220
Cutting speed (m/min)

Fig. 2. Main effects plot for surface roughness (Ra) Fig. 3. Effect of cutting speed on the machined workpiece surface
temperature and surface roughness (f= 0.13 mm/rev, d= 0.4 mm)

Fig. 4. SEM images of the surface quality noticed in turning hardened AISI 4340 steel: (a) v = 100 m/min, f = 0.05 mm/rev, d = 0.2 mm (run no.
1); and (b) v = 220 m/min, f = 0.09 mm/rev, d = 0.2 mm (run no. 8)

3.2. Tool wear analysis

Table 5 represents the results of ANOVA for flank wear (VB). The results revealed the amount of flank wear is
greatly influenced by cutting speed, followed by feed and lastly by depth of cut. Examination of P-value shows
cutting speed and feed are the significant factors on flank wear (VB), which have contributed 81.93% and 15.23%
respectively. The factor depth of cut does not present statistical significance on the obtained flank wear because of
its smaller F calculated value at 10% level of significance and accounting for only 1.81% of the total variability.
The main effect plots for tool flank wear (VB) in Fig. 5 indicates that flank wear increases with cutting speed and
feed, resulting in abrasion marks (see, Fig. 6) due to sever rubbing effect between tool flank and machined surface
by hard carbide in steels, broken-away particles from the cutting edge [20]. Another way; the increase of flank wear
can be explained due to the high centralization of the compressive stresses at the tool’s rake face near to the cutting
edge and also because of the normal high tool temperatures which leads to high cutting edge loads or reduced the
hardness of tool due to thermal softening at the vicinity of cutting edge.
6566 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569

Table 5. ANOVA for flank wear (VB)

Source DOF Seq. SS Adj. SS Adj. MS F P-value C (%)
v 2 0.0206296 0.0206296 0.0103148 79.48 0.012 81.93
f 2 0.0038336 0.0038336 0.0019168 14.77 0.063 15.23
d 2 0.0004562 0.0004562 0.0002281 1.76 0.363 1.81
Error 2 0.0002596 0.0002596 0.0001298 1.03
Total 8 0.0251789 100
S= 0.011392 R-Sq= 98.97% R-Sq(adj)= 95.88%

Fig. 5. Main effects plot for flank wear (VB) Fig. 6. SEM image of flank wear in a worn out coated carbide
insert at v= 220 m/min, f = 0.09 mm/rev and d = 0.2 mm

3.3. Chip morphology analysis

Fig. 7 confirms the formation of saw tooth type chip due to periodic crack propagation during hard turning of
AISI 4340 steel. In analyzing the chip morphology, it was noticed that severity of serration occurred in the free (top)
surface of chip, including lateral flow and shear cracks could be attributed to plastic deformation of chips due to rise
in temperature during machining. As the feed reduced and the cutting speed increased, a reduction of chip thickness
is occurred (see, Fig. 8) and produced chips of three categories, i.e. long helical washer type broken chips, long and
snarled unbroken chips and ribbon type chips. As reported by Tamizhamanii and Hasan [21] this is due to substantial
contact area on the rake face and small shear plane area at low cutting speed will result in thinner chips. In contrast,
increase in chip thickness due to increased feed because of severe compressive stresses ahead of the tool rake,
thereby large volume of material becomes totally plastic which results in thick chip, as reported in earlier report [22].

3.4. Correlation

The relationship between the factors (v, f & d) and the performance characteristics (Ra & VB) were performed by
multiple regression analysis. The following models were suggested:

Ra = 1.05 – 0.0014*cutting speed + 2.43*feed - 0.212*depth of cut (R2=87%) (1)

VB = - 0.0969 + 0.000969*cutting speed + 0.604*feed + 0.0433*depth of cut (R2=96%) (2)

 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569 6567

Value of R2 decides the efficacy of model which can be reasonably adopted for surface roughness and tool’s
flank wear. The obtained R2 values of the regression models for surface roughness (Ra) and flank wear (VB) are
87% and 96% respectively, indicated the results at a high significance of model. Fig. 9 shows the normal probability
plot of surface roughness and flank wear, where residuals follow straight line which clearly approximates the
predicted and experimental values. With P-value (0.721 for Ra and 0.98 for VB) obtained from Anderson-Darling
test is greater than alpha (α) of 0.05 (level of significance) which accepts the normal distribution of data and
adequacy of the model.

Fig. 7. SEM observation of chip morphology at v = 220 m/min, f =

0.09 mm/rev and d = 0.2 mm.

Fig. 8. Chip thickness at different cutting speeds

Fig. 9. Normal probability plot of surface roughness and flank wear Fig. 10. Response optimization plot for surface roughness (Ra)
6568 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569

3.5. Cost analysis

Due to increasing demand of quality product at lowest cost and to replace cylindrical grinding, cost consciousness
in hard turning is an important aspect and crucial factor for an efficient manufacturing system. Generally, under
optimized cutting conditions of process parameters, assessment of tool life judges the competence of machining
process and reduction of machining cost. In hard turning, response surface optimization is mostly preferred for
optimization of machining parameters. Fig. 10 shows the RSM optimization outcome for surface roughness. The
optimum cutting condition for surface roughness are in the region of cutting speed (v) = 220 m/min, feed (f) = 0.087
mm/rev and depth of cut (d) = 0.52 mm, which resulted the optimized surface roughness value (Ra) of 0.447 µm.
Finally, an experimental run was carried out under dry environment to evaluate the tool life at optimum cutting
parameters (obtained by RSM technique) considering the criterion of surface roughness (Ra) rise above the value of
1.6 μm. In turning hardened AISI 4340 steel with multilayer TiN/TiCN/Al2O3/TiN coated carbide insert, the tool life
is observed about 39 minutes. The estimation of cost (total machining cost per part), was evaluated (39 min)
according to Gilbert’s approach [5,23,24]. From Table 6, it is found that approximate total machining cost per part
using coated carbide inserts is Rs. 8.21.

Table 6. Machining cost per part for coated carbide insert in turning AISI 4340 hardened steel
Workpiece= AISI 4340 (49 HRC), finished w/p diameter (D)= 72 mm, cutting conditions: cutting speed (v)= 220 m/min, feed (f)= 0.087 mm/rev,
depth of cut (d)= 0.52 mm, machining length (L)= 100 mm, tool life for single edge (T)= 39 min, machining time per part (Tc)= πDL/1000vf =
1.18 min, machine downtime (Td)= 5 min.
No. Costs Coated carbide
1 Value of machine and operator, Rs.200/h (x) Rs. 3.33/min
2 Machining cost/part (xTc) Rs. 3.93
3 Tool changing cost/part [xTd(Tc⁄T)] Rs. 0.50
4 Tool insert cost/piece Rs. 500
5 Average cost of single cutting edge (y) Rs. 125
6 Total cost/part [y(Tc⁄T)] Rs. 3.78
7 Total machining cost per part (C), (2+3+6) Rs. 8.21

4. Conclusions

Based on the experimental results and subsequent analysis, the following conclusions are drawn:

• ANOVA analysis indicates that feed was the most significant parameter for surface roughness followed by
cutting speed, affecting by about 70% and 22% respectively. The surface roughness is continuously
decreased with the increase in cutting speed, whereas surface finish improved with increasing feed (upto
0.05 mm/rev) and occurred a significant deterioration of surface roughness with further increasing feed.
• Cutting speed is the cutting condition that has the highest physical as well as statistical influence on the tool
flank wear (81.93%) right after feed (15.23%), whilst the depth of cut has a less effect (1.81%). Increase of
all three parameters (v, f, d) affects the tool wear positively.
• From SEM observation, abrasion was found to be the main wear mechanism of TiN/TiCN/Al2O3/TiN coated
carbide tool. From SEM micrograph, machined surface indicates feed marks, adhered oxides and chip
particles, surface voids, material side flow, un-machined material, smooth and rough surface at the surface
obtained best and poor surface finish in hard turning of AISI 4340 steel with coated carbide tool.
• Chip serration causes the formation of saw tooth chip due to cyclic crack at the free surface of the chip as a
result of severe plastic deformation. With cutting parameters in the current study, increasing the cutting
speed and decreasing the feed produced thinner chips (smaller chip thickness).
 Sudhansu et al. / Materials Today: Proceedings 5 (2018) 6560–6569 6569

• Multiple linear regression models were developed for surface roughness and flank wear. The proposed
models are adequate and statistically valid because of higher R2 value (0.87 for Ra and 0.96 for VB) and null
hypothesis (P-value greater than 0.05; Anderson-Darling test).
• It has been observed that the total machining cost per part using CVD multilayer TiN/TiCN/Al2O3/TiN
coated carbide inserts is nearly Rs. 8.21 based on a single cutting edge under optimum cutting conditions
(v= 220 m/min, f= 0.087 mm/rev and d= 0.52 mm) resulting higher tool life (39 min), magnificent for hard
turning applications.
• From the study, the effectiveness and potential of multilayer TiN/TiCN/Al2O3/TiN coated carbide tool for
hard turning process during dry cutting condition possesses high yielding and cost-effective benefit to
substitute the traditional cylindrical grinding operation. Apart, it also contributes reasonable option to
costlier CBN and ceramic tools.

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