Application of response surface methodology for determining cutting force model in turning hardened AISI H11 hot work tool steel

This experimental study is conducted to determine statistical models of cutting forces in hard turning of AISI H11 hot work tool steel (similar to 50 HRC). This steel is free from tungsten on Cr-Mo-V basis, insensitive to temperature changes and having a high wear resistance. It is employed for the manufacture of highly stressed diecasting moulds and inserts with high tool life expectancy, plastic moulds subject to high stress, helicopter rotor blades and forging dies. The workpiece is machined by a mixed ceramic tool (insert CC650 of chemical composition 70%Al2O3+30%TiC) under dry conditions. Based on 33 full factorial design, a total of 27 tests were carried out. The range of each parameter is set at three different levels, namely low, medium and high. Mathematical models were deduced by software Minitab (multiple linear regression and response surface methodology) in order to express the influence degree of the main cutting variables such as cutting speed, feed rate and depth of cut on cutting force components. These models would be helpful in selecting cutting variables for optimization of hard cutting process. The results indicate that the depth of cut is the dominant factor affecting cutting force components. The feed rate influences tangential cutting force more than radial and axial forces. The cutting speed affects radial force more than tangential and axial forces.