Sunil Thesis Dec

NIT HAMIRPUR (H.P)

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

Effect of cutting speed on output regimesEffect of cutting speed on output regimesREF.NO. Astakhov V.P. and Osman M.O.M. (1996) CS Forces CT BUE TW CP SR TL

FC Astakhov V.P. and Osman M.O.M. (1996)Astakhov V.P. and Osman M.O.M. (1996)

FF

FP

o

Marusich Troy D. (2001)Astakhov Viktor P. and Shvets S. (2004) Saglam Haci, et al. (2007) Astakhov V.P. and Outeiro J.C. (2006)

o

o

Kopac Janez, et al. (2002)Mufioz-E. P. and Cassier Z., (1998) Ciftci Ibrahim, (2006) Senthil Kumar, et al.( 2006) Noordin M.Y., et al. (2007) Sharma V S, et al.( 2007) Sharma Vishal, et al.( 2008) Astakhov Viktor P., (2004)

o

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.

Effect of feed rate on output regimesEffect of feed rate on output regimesREF.NO. FR Forces FC Astakhov V.P. and Outeiro J.C. (2006) Astakhov V.P. and Outeiro J.C. (2006) Astakhov V.P. and Outeiro J.C. (2006) Mufioz-E. P. and Cassier Z., (1998) Sharma Vishal, et al.( 2008) Grzesik W. and Wanat T., (2006) Paro J.A., et al. (2004) Noordin M.Y., et al. (2007) Sharma V S, et al. ( 2007) Sharma V S, et al. ( 2008) 600m/min( in case of PCBN with multi layer hard coatings. With the use of hard surface coating tool life increases by a factor of 2-3 by reducing the rate of wear.

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.

Gaps in the existence studyMedium carbon steels are commercially used in the industry. o Very few researchers has reported the influence of input cutting regimes on output regimes such as cutting forces , roughness, cutting power under dry conditions with different tool materials on EN-31 (AISI52100) high carbon steel. o Moreover very few researchers have studied the combined effect of approach angle, cutting speed, feed and depth of cut on cutting forces, tool tip temperature, surface roughness, cutting power and specific cutting pressure.

ObjectivesAfter 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

y

x

y

x

e

s

r(inch)

Tool reference systems: In this configuration of tool is taken as reference.

Tool signature is designated in sequence as:Inclination angle Rake angle Clearance angle Auxiliary clearance angle End cutting edge angle Principle cutting edge angle Nose radius

o

o

o'

1

1

r(mm)

MethodologyThe study is divided broadly into four phases

Phase 1 Phase 2 Phase 3 Phase 4

Material processing's

Experimentation

Data analysis

Optimization

Input cutting regimes Approaching angle Speed

Feed Depth of cut

Output cutting regimes Cutting forces: Fc (cutting force),

Fp (Passive force) Ff (Feed force) Tool tip temperature (tt) Cutting power Cutting pressure Surface roughness (ra)

Methodology to achieve the listed objectivesThe objectives were achieved by carrying out the following functions during machining of EN-31 steel carbide tool inserts (Two different coatings) and cermet inserts under dry conditions and at different cutting parameters. Measuring and analyzing the cutting forces namely cutting force (Fc), feed force (Ff) and passive force (Fp) on-line during machining. Measuring & analyzing the tool tip temperature (Tt) on-line while machining. Measuring & analyzing power (P) and cutting pressure (Kc) on-line during machining. Off-line measurement of the surface roughness after each machining cycle.

Optimization of cutting parameters while minimizing the machining variables experimentally.Validation of the optimized cutting parameters & machining variables obtained experimentally by RSM

Phase 1Material procured EN-31Study of properties of material

Heat treatment

Chemical composition test

Microstructure test

Throughout hardening: Temp: 840C For 1 hr., Oil quenched

Tempering: Temp: 550C for 2 hr., air cooled

Chemical composition C: 0.97 Si: 0.22 Mn: 0.30 P:0.011 S: 0.006 Cr: 1.41

Microstructure before test: Fine globular carbide in matrix of ferrite

Results : Observed hardness 337-356 BHN

Microstructure after test: Fine globular carbides in the matrix of tempered martensite

Hardness testingEquipment 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)

Hardness of raw material

Hardness of hardened & tempered

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)

Observed hardness after tempering: 343,341,337 BHN 10/3000 (36,37,36 HRC)

2Hr

5305

Chemical compositionSample polished with rotating 60 no(grit size) emery paperSample MarkEN-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 tester

Output Off line data

Surface roughnessWorkpiece

Cutting forces , temperature, Cutting power

Tool tip temperature sensor

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

Fixture for holding dynamometerProblems with old fixture back rake angle and end clearance angle was varied by approximately 15 and due to rough use of this fixture there was Significant amount of wear and tear in tapered slot which varied the values of side clearance and side rake angle and there was frictional rubbing od side clearance face with finished workpiece due to this rubbing wear occurs in side clearance face and workpiece surface finish also destroys.

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.

Fixture for holding dynamometer

Fixture for holding dynamometer

Workpiece material

USUAL CHEMICAL COMPOSITION:

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

Indian standard designation: 105 Cr 1 Other equivalents: En No. 31 SAE 51100 52100 AISI E51100 E52100

DESIGN OF EXPERIMENTSTool Material Coated carbide inserts and cermet insertCCMT09T304.

Approaching Angle (degree)

45 , 60, 75, 90

Speed (m/min)

80,110,140,170

Feed rate (mm/rev)

0.10,0.12,0.14,0.16

Depth of Cut (mm)

0.5

Rake angle (degree)

60

Design of experiment for T1,T2,T3Run 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Cutting Speed (m/min) 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 Feed (mm/rev) 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 Approach Angle (degree) Constant 45 45 45 45 60 60 60 60 75 75 75 75 90 90 90 90 45 45 45 45 60 60 60 60 75 75 75 75 90 90

Design of experiment for T1,T2,T3Run33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Cutting Speed (m/min)80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110 140 170 80 110

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

Approach Angle (degree) Constant 45 45 45 45 60 60 60 60 75 75 75 75 90 90 90 90 45 45 45 45 60 60 60 60 75 75 75 75 90 90

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