Experimental and Finite Element Analyses for High-Speed Machining of AISI 4340 steel with ZTA Insert

Zirconia-toughened alumina was developed via chemical co-precipitation route, followed by powder metallurgy route to develop inserts, upholding all standard procedures. AISI 4340 (HRC 19) was turned in a speed range of 210–350 m/min, feed rate of 0.08–0.2 mm/rev and depth of cut 0.5–1.5 mm to investigate the performance. Optimum machining parameters giving minimum cutting force components were found out using response surface methodology. Strain rate at the shear zone was evaluated under all the machining conditions using finite element analysis (FEA). A three-dimensional implicit Lagrangian computational model was developed using Deform 3D software to execute the FEA. The maximum stress and strain rate were found to be 1311 MPa and 58,109 s−1 at the operating condition of 350 m/min speed, 1.5 mm depth of cut and 0.08 mm/min feed rate. This clearly indicates the potential of cutting insert suitable for high-speed machining.