| Summary: | X40CrMoV5-1 hot work tool steel is commonly used in injection and extrusion molds and also manufacturing of parts requiring high temperature, toughness and abrasion resistance. On the
other hand, the preference of hard turning instead of grinding reduces the production time and cost, while improving the fatigue strength of the part in the case of putting the cylindrical parts
into final form. In this study, the main cutting force (Fc) was investigated experimentally and numerically during machining of hardened X40CrMoV5-1 tool steel with vacuum and heat treatment to 55 ± 1 HRC by coated and uncoated ceramic inserts. Hard turning experiments were performed according to the Taguchi L32 experimental design using different levels of cutting
parameters (feed rate, cutting speed and depth of cut). Kistler 9257B dynamometer and equipments were used in experimentally determination of Fc values. Cutting simulations based on the finite element method were performed in DEFORM 3D software. In addition, the effects of cutting parameter on Fc were identified via analysis of variance (ANOVA) at 95% assurance level. The similarity between experimental and numerical analysis results for Fc values was found to be 94% for uncoated tools and 91% for coated tools. It was determined that depth of cut is the most important factor according to ANOVA results obtained by using experimental data.
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