Abstract
Based on the several studies conducted, dry hard turning is more beneficial practical process compared to a grinding operation, it increases quality, reduces cost and lead-time for machined parts. In this study, effects of workpiece hardness, feed rate, depth of cut and cutting speed on surface roughness were studied using chamfered and honed CBN inserts. Effects of surface roughness on wear resistance in finish hard turning of AISI D2 tool steel experimentally and analytically is investigated. Four factors (hardness, depth of cut, feed rate and cutting speed) were considered and - two level fractional experiments were conducted and analysis of the variance was performed. Further more this study shows that the effects of grinding of heat treated AISI D2 specimens on surface roughness were conducted and a comparison took place with hard turning. Due to wear rate being considered as an important factor of workpiece life, the block-on-ring wear test was used to evaluate the machined parts; the effect of surface roughness on wear resistance was investigated and plotted. To investigate the effect of temperature increase on both techniques, the machined surface of workpieces is examined using optical and scanning electron microscopy SEM. Practical results shows the lower workpiece hardness and lower cutting conditions resulted in a better surface roughness. Finally surface roughness and workpiece hardness found affectedin wear resistance. And the wear was graphically analyzed.