Abstract

Wiper inserts have the characteristics of eliminating many grinding operations and achieving an excellent surface. They also improve component quality and roundness compared with grinding. This paper exposes a performance comparative analysis, involving the criteria of surface roughness (R_a, R_t and R_z) during high strength steel’s turning operation, between the conventional and wiper inserts. The main parameters considered in this study are; the speed of cutting (CS), the feed rate (FR), and the cutting depth (DOC). The test plan was carried-out through (128) test specimens divided into two equal sample groups (A and B), each consists of (64) test specimens. Specimens of group (A) and (B) are tested using wiper and conventional inserts respectively. To apply the required testing conditions, a CNC Turning machine equipped with Sinumeric 840-D, was used. The surface roughness was evaluated using a surface roughness tester (Tesa-rugosurf 90- G). The most important parameters affecting the surface roughness are highlighted. Statistical tests used for this study including the analysis of variance (ANOVA) and the response surface methodology (RSM) are presented. The results show the significance of cutting depth and feed rate in the reduction of surface roughness. The machining conditions producing the optimum roughness of the surface, in the experiment range, were investigated using desirability-function-approach for the optimization of multiple-factors of response. The results showed that the quality of surface derived with the wiper carbide insert has significant improvement in comparison to the conventional carbide insert. The maximum improvement of 3.5 times between the wiper insert and conventional insert was achieved at a surfacing speed of 75 meter/min and is limited to 3, 2.5 and 2 times for a surfacing speed of 100, 125 and 150 meter/min, respectively.

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