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Contents
Introduction Literature survey Gaps in the existence study Objectives Methodology adopted Experimental setup Design of experiment
references
Introduction
Metal machining is a purposeful fracture for removal of material in the form of chips to give work piece desired dimensions by using wedge shaped cutting tools. Approximately 15% of cost of all mechanical parts worldwide is derived from machining operation and nearly 70 to 80% parts are machined before they are put into the use, Merchant M.E(1998). Optimization of cutting power is important in manufacturing industry for reducing the energy required in the making of products. For optimizing cutting power there is a requirement of proper selection of cutting tool geometry, materials and coatings, input cutting regimes and respective work piece materials.
Literature survey
Effect of cutting speed on output regimes Effect of feed rate on output regimes Effect of depth of cut on output regimes Effect of approach angle on output regimes Effect of tool geometry on output regimes
FF
FP
CS: Cutting Speed, FC: Cutting Force, FF: Feed Force, FP: Passive Force, CT: Cutting Temperature, BUE: built up edge, TW: Tool Wear, CP: Cutting Power, SR: Surface Roughness, : Increase, : Decrease, o: optimum value.
FR: Feed Rate, FC: Cutting Force, FF: Feed Force, FP: Passive Force, CT: Cutting Temperature, TW: Tool Wear, CP: Cutting Power, SR: Surface Roughness, TG: tool geometry, TL: tool life, : Increase, : Decrease, Bt: Below optimum cutting temperature, At: Above optimum cutting temperature, Lt: Less than transient surface
DC
FC Astakhov V.P. and Outeiro J.C. (2006) Baldoukas, A. K. et al. (2008) Mufioz-E. P. and Cassier Z., (1998) Sharma V S, et al.( 2007) o
Forces
FF FP
CT
TW
CP
SR TL
DC: Depth of Cut, FC: Cutting Force, FF: Feed Force, FP: Passive Force, CT: Cutting Temperature, TW: Tool Wear, CP: Cutting Power, SR: Surface Roughness, TG: tool geometry, TL, tool life. : No change, : Increase, : Decrease, o: optimum value.
REF.NO. AA Forces CT TW CP SR TL
FC
FF
FP
AA Approach Angle, FC: Cutting Force, FF: Feed Force, FP: Passive Force, CT: Cutting Temperature, TW: Tool Wear, CP: Cutting Power, SR: Surface Roughness, TG: tool geometry, tool life, : Increase, : Decrease.
12
Rn
Rp Nr Ci Rp Rn
0-2.5
0-20
TG: tool geometry, FC: Cutting Force, FF: Feed Force, FP: Passive Force, CT: Cutting Temperature, TW: Tool Wear, CP: Cutting Power, SR: Surface Roughness, : Increase, : Decrease, Rp: positive rake angle, Rn: negative rake angle, Nr: nose radius., Ci: coated inserts, Ni: nose radius, Lt: Less than transient surface
Literature survey
Table
(Ciftci Ibrahim): Concluded that surface coatings (TiC/TiCN/TiN) reduces the tendency of BUE formation and surface roughness and cutting forces deceases due to low coefficient friction of Tin top coating layer.
(C. Lim): Concluded that with the use of TiN coating on HSS tools tool wear rate decreases so tool life increases so we can use more higher speed and feeds for obtaining efficient machining.
(W. Grzesik): Concluded that with the use of surface coating forces and power required is less and with TiC/TiN multi layer coating this reduction reaches to 20%
(C. Wuyi): Concluded that with the use of hard cutting tool materials higher cutting speed can be obtained and surface finish increases and tool wear rate also decreases.
Upper layer of TiN on multi layer surface reduce power requirement for cutting up to 20%.
TiN layer reduces BUE problem by reducing adhesion on tool rake face. Due to temperature resistance of multi layer coatings tool temperature decreases due to decrease in tool chip contact so we can use dry machining and we can save 16-20% machining cost with respect to flood lubrication.
Objectives
After going through the literature the following objectives were set to carry out the research work. o To measure the cutting forces such as Fc, Ff and Fp , power, cutting pressure , tool tip temperature on-line at different approach angle, speed and feed and during machining of the materials namely EN-31 with carbide tool inserts (Two different coatings) and cermet inserts under dry conditions. o To measure surface roughness off-line at different approach angle, speed and feed and during machining of the materials namely EN-31 with carbide tool inserts (Two different coatings) and cermet inserts under dry conditions. o Analysis of experimental data. o Optimization of data.
Tool Geometry
Various systems for designating tool geometries are:
Tool in hand system
Machine reference system: Also known as ASA( American standard association system) system. In this configuration of machine is taken as reference. Tool signature is designated in sequence as:
Bake rake angle Side rake angle End clearance angle Side clearance angle End cutting edge angle Side cutting edge angle Nose radius
r(inch)
o'
r(mm)
Methodology
The study is divided broadly into four phases
Material processing's
Experimentation
Data analysis
Optimization
Feed
Depth of cut
Fp (Passive force)
Ff (Feed force) Tool tip temperature (tt) Cutting power Cutting pressure Surface roughness (ra)
Phase 1
Material procured EN-31
Study of properties of material
Heat treatment
Microstructure test
Chemical composition C: 0.97 Si: 0.22 Mn: 0.30 P:0.011 S: 0.006 Cr: 1.41
Microstructure after test: Fine globular carbides in the matrix of tempered martensite
Hardness testing
Equipment Used : Optical Brinell Hardness tester. Make Fie, India Model BHN(O)
Pcs No.1: 170,169,170 HBW 10/3000 3,3,3(HRC) Pcs No.2: 170,169,168 HBW 10/3000 3,3,3(HRC) Pcs No.3: 169,169,170 HBW 10/3000 3,3,3(HRC)
Pcs No.1: 343,341,337 HBW 10/3000 (36,37,36 HRC) Pcs No.2: 340,337,335 HBW 10/3000 (36,37,37 HRC) Pcs No.3: 345,343,345 HBW 10/3000 (37,36,37 HRC)
Throughout hardening
Quenching oil used: Meta quench 39 (HPCL) oil. Flash point 200C, oil temperature when quench 60C Required hardness: 32-40HRC Observed hardness: 495-520BHN 10/3000 (51-53HRC)
1Hr
8405
Tempering
Observed hardness before tempering: 495-520BHN 10/3000 (51-53HRC)
2Hr
5305
Chemical composition
Sample polished with rotating 60 no(grit size) emery paper
Sample Mark
EN-31 C 0.97 Si 0.22 Mn 0.30 P 0.011 S 0.006 Ni ---Cr 1.41 Mo ------
Equipment Used:
Spark Emission Spectrometer , Make: BAIRD USA, Model: DV6, Test Method : ASTM : E415 -2008
Experimental set up
Chuck
Surface roughness
Workpiece
Insert
Data Acquisition card Turning Dynamometer Forces Signal processing Output Online data
Temperature
Instrumentation used
Turning dynamometer (3 components TeLC Germany) Tool tip temperature sensor (Infrared) Surface roughness tester (Mitotoyo SJ-301) Brinell hardness tester (Optical Brinell Hardness tester), Make Fie, India. Spark Emission Spectrometer, (Make: BAIRD USA, Model: DV6) Microscope (Make: Nikon, Japan, Magnification 50X to1000X) CNC turning Centre
New design of fixture tapered slot was replaced with parallel slot with respect to slot provided for tool holding in machine turret. Then the centre height was maintained by prototyping. Then the design was converted into real fixture by machining on shaper and milling machine tools.
Workpiece material
C (0.9-1.2)%
Si 0.1-0.35%
Mn 0.2-0.8%
Cr 1.0-1.6%
Application:- Used for ball and roller bearing, bearing rings, bushed, collects, cams, lathe centre
DESIGN OF EXPERIMENTS
Tool Material Coated carbide inserts and cermet insert
CCMT09T304.
45 , 60, 75, 90
Speed (m/min)
80,110,140,170
0.10,0.12,0.14,0.16
0.5
60
Feed (mm/rev)
0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.14 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16 0.16
References
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