An experimental study of the effect of high-pressure water jet assisted turning (HPWJAT) on the surface integrity (original) (raw)
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Residual Stress in High-Pressure Water Jet Assisted Turning of Austenitic Stainless Steel
Materials Science Forum, 2006
This study deals with the effect of High-Pressure Water Jet Assisted Turning (HPWJAT) of austenitic stainless steels on chip shape and residual stresses. The machining of the austenitic stainless steels represents several difficulties. Recently, research has shown that the introduction of a high-pressure water jet into the gap between the tool and the chip interface is a very satisfactory method for machining applications. In this article, the effect of a high-pressure water jet, directed into the toolchip interface, on chip shapes breakage and surface integrity in face turning operations of AISI 316L steel has been investigated. Tests have been carried out with a standard cutting tool. The cutting speeds used were 80 and 150 m/min, with a constant feed rate of 0.1 mm/rev and a constant cutting depth of 1 mm. Three jet pressures were used: 20, 50 and 80 MPa. Residual stress profiles have been analysed using the X-ray diffraction method in both longitudinal and transversal directions. The results show that jet pressure and cutting parameters influence the residual stresses and the chip shapes.
New trends in cutting technologies: application of high pressure jet assisted machining
High Pressure Jet Assisted Machining (HPJAM) in turning is a hybrid machining method in which a high pressure jet of cooling and lubrication fluid is directed to the contact zone between chip and cutting tool. It uses in highly productive processes of chip removal - roughing and semi-machining. This paper shows that the application of HPJAM offers great advantages in regarding of materials machinability. Workpiece material used in experimental research in turning process was the construction carbon steel C45E with hardness of 45 HRc and alloyed bearings steel with high resistance to wear 100Cr6 and hardness of 62 HRc. Experimental researches are performed, and material machinability in metal cutting is analyzed.
International Journal of Advanced Manufacturing Technology, 2000
Behavior of austenitic stainless steels has been studied at very high cutting speeds. Turning tests were carried out using the AISI 303 austenitic stainless steel. In particular, the influence of cutting speed on tool wear, surface quality, cutting forces and chip geometry has been investigated. These parameters have been compared when performing machining at traditional cutting speeds (lower than 350 m/min) versus high cutting speeds. The analysis of results shows that the material undergoes a significant change in its behavior when machining at cutting speeds above 450 m/min, that favors the machining operation. The main component of cutting forces reaches a minimum value at this cutting speed. The SEM micrographs of the machined surfaces show how at the traditional cutting speeds the machined surfaces contain cavities, metal debris and feed marks with smeared material particles. Surfaces machined at high cutting speeds show evidence of material side flow, which is more evident at cutting speeds above 600 m/min. Tool wear is located at the tool nose radius for lower cutting speeds, whereas it slides toward the secondary edge when cutting speed increases. An analysis of chips indicates also an important decrement in chip thickness for cutting speeds above 450 m/min. This study concludes that there is an unexplored range of cutting speeds very interesting for high-performance machining. In this range, the behavior of stainless steels is very favorable although tool wear rate is also significant. Nevertheless, nowadays the cost of tool inserts can be considered as secondary when comparing to other operation costs, for instance the machine hourly cost for high-end multitasking machines.
International Journal of Engineering Research and, 2017
The purpose of this experimental investigation is to determine the influence of cutting fluids on tool wear and surface roughness during turning of AISI 316 with carbide tool. An attempt has been made to identify the influence of coconut oil (vegetable based cutting fluid) to improve efficiency of machining process. The efficiency of machining process depends up on various parameters like surface roughness on the work piece, temperature developed on tool chip interface, tool wear etc. The machining process is carried out with the help of four different machining parameters namely cutting speed, depth of cut, feed rate and the type of cutting fluid used. By varying these parameters, the surface roughness and tool wear are measured for three different cutting fluids namely coconut oil, straight cutting oil (immiscible with water) and water soluble oil. It has been found that the performance of coconut oil in reducing the tool wear and surface roughness during turning of AISI 316 steel is better compared to the other two cutting fluids. Coconut oil is used as one of the cutting fluids in this work due to its thermal and oxidative stability which is comparable to other vegetable based cutting fluids used in the metal cutting industry.
Study of machining parameters while turning austenitic stainless steel AISI304
Stainless steels are hard materials and difficult to machine as seen in research work done until now. A machining industry which aims for higher quality and higher productivity at low cost, will definitely face problem with elevated temperatures at the metal cutting zone during the machining process, as the conventional cooling methods fail to reduce the heat at tool-chip interface thereby affecting the performance. This problem can be handled largely by reducing the cutting temperature. Hence, a cryogenic coolant is highly recommended for this purpose. Based on the results obtained from the experimental work done until now, it can be concluded that machining with the cryogenic CO2 cooling had a substantial benefit with respect to the cutting temperature, cutting forces, chip thickness and morphology, surface roughness, shear angle, and tool wear, when compared with the other conventional cooling methods. In this project, works on the various machining parameters affecting the effectiveness of turning AISI 304 are reviewed for improving surface finish. Process parameters such as cutting speed, feed rate, depth of cut mainly under conventional cooling and cryogenic cooling conditions are considered. Cryogenic cooling setup for supplying CO2 gas was developed. The work material Austenitic stainless steel AISI 304 is selected for performing various experimentations. The result is further confirmed by experiments. Finally output parameters like surface finish can be optimized for economical production.
Metals, 2021
Sustainable manufacturing has received great attention in the last few decades for obtaining high quality products with minimal costs and minimal negative impacts on environment. Sustainable machining is one of the main sustainable manufacturing branches, which is concerned with improving environmental conditions, reducing power consumption, and minimizing machining costs. In the current study, the performance of three sustainable machining techniques, namely dry, compressed air cooling, and minimum quantity lubrication, is compared with conventional flood machining during the turning of austenitic stainless steel (Nitronic 60). This alloy is widely used in aerospace engine components, medical applications, gas power industries, and nuclear power systems due to its superior mechanical and thermal properties. Machining was performed using SiAlON ceramic tool with four different cutting speeds, feeds and a constant depth of cut. Consequently, various chip characteristics such as chip ...
IOP conference series, 2018
The primary method of material removal from a cylindrical workpiece is conceivable by using turning process.This paper presents a comprehensive analysis of surface integrity in dry machining of AISI 410 martensitic stainless steel which is widely used material for automotive and aerospace applications. In the present work, the effects of turning process parameters such as cutting velocity, feed and depth of cut in dry turning of martensiticstainless steel has been investigated. Taguchi orthogonal array has been implemented to investigate the effect of process parameters on surface roughness and tool-workpiece interface temperature. A detailed study about the chip morphology and machined surface has been carried out using scanning electron microscope. It was noticed that golden color thick long ribbon type chip was produced at dry condition and side flow has been observed in chip.
Study of high-pressure abrasive water jet capacity indices for steep cutting of steels
Mechanik
Quality of the technological part is one of the major problems of modern machine manufacturing. In many cases, components are manufactured from new construction materials with specific properties that are considered difficult to machining applying conventional technologies. Hence, to search for new technologies, including high-pressure abrasive water jet cutting in the context of the S355J2H steel elements manufacture, while maintaining the quality requirements of the machining, is the need. The results of tests on the accuracy of components made of S355J2H steel are presented as dependent on the water jet pressure, cutting feedrate and the amount of abrasive dozed, with constant element thickness. The accuracy of the design measure – regardless of dimensional accuracy – was the magnitude of the lateral sagging of the cut workpiece resulting from the specific mechanism of water jet removal mechanism.
Journal of Mechanical Engineering, 2015
Hard turning of harder material differs from conventional turning because of its larger specific cutting forces requirements. The beneficial effects of hard turning can be offset by excessive temperature generation which causes rapid tool wear or premature tool failure if the brittle cutting tools required for hard turning are not used properly. Under these considerations, the concept of high-pressure coolant (HPC) presents itself as a possible solution for high speed machining in achieving slow tool wear while maintaining cutting forces at reasonable levels, if the high pressure cooling parameters can be strategically tuned. This paper deals with an experimental investigation of some aspects of the turning process applied on hardened steel (HRC48) using coated carbide tool under high-pressure coolant, comparing it with dry cut. The results indicate that the use of high-pressure coolant leads to reduced surface roughness, delayed tool flank wear, and lower cutting temperature, while also having a minimal effect on the cutting forces.