Experimental Studies to Investigate the Cutting Forces, Surface Roughness and Tool Wear in the Machining Process of Hardened AISI 4140

In this research, the effect of parameters of cutting speed, feed rate and machining time at constant cutting depth on tool wear and its effect on the surface roughness of hardened steel 4140 and machining forces were investigated. First, 4140 steel was prepared and its hardness was increased to 45 HRC under heat treatment, and then the TCMW 16T304 H13A tool was prepared from uncoated cemented carbide for machining. The design of the experiments was carried out in a full factorial manner. The analysis of the results was done from the analysis of variance test and the graphs related to the experimental results, based on these results, the advance rate had the greatest effect on the surface roughness and machining shear force, and the machining time had the greatest effect on the machining advance force and Cutting speed also had the greatest effect on tool wear. The highest amount of tool wear was equal to 0.89 mm and the lowest amount of tool wear was equal to 0.41 mm. The best surface quality was measured as 0.372 μm and the highest surface roughness was measured as 1.154 μm. The maximum shear force was 172.7 N and the minimum shear force was 54.2 N. The maximum forward force was equal to 156.59 N and the minimum forward force was equal to 45.86 N.