IJERT-Modeling and Analysis of Effect of Cutting Parameters on Product Quality in Dry Turning Operation of Mild Steel using Carbide & High Speed Steel Tool (original) (raw)
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In turning many key factors like, type of tool bit and its setting angle, machining conditions, type of material to be machined, spindle speed, cutting speed and feed rate etc., plays an important role. Out of all tool bit and cutting speed plays vital role. In this study, on lathe Machine Turning operation has been carried out for different Steel materials such as Mild Steel, EN-8, EN-31 and OHNS by maintaining constant depth of cut and feed by using DNMG 110404 carbide insert tool bit and then with High speed steel (HSS) tool bit at various cutting speeds 400, 800, 1200, 1600 rpm respectively. The surface roughness values have been compared for both the tool bits and the cutting force values have been analyzed for carbide insert tool bit. From the study the effectiveness of carbide insert tool bit has been noticed for steel materials at various cutting speeds in turning operation.
International Journal of Engineering Research and Technology (IJERT), 2014
https://www.ijert.org/a-study-on-effect-of-basic-cutting-variables-on-machining-characterestics-of-low-carbon-steel-work-material-in-turning https://www.ijert.org/research/a-study-on-effect-of-basic-cutting-variables-on-machining-characterestics-of-low-carbon-steel-work-material-in-turning-IJERTV3IS080566.pdf Machining is the most versatile manufacturing process and is influenced by a number of cutting parameters. The selection of parameters values for optimum result and maximizing material removal rate is crucial in realizing economy in manufacturing. The present work is aimed to establish the influence of feed, depth of cut and cutting speed on cutting characteristics of a standard work-material like Low Carbon steel under dry and wet conditions of machining. Using the cutting force data, an empirical model for power component of cutting force was developed. The goodness of fit of the model with the data was also tested. The surface roughness measurement indicates better surface finish with smaller feed magnitude and increased magnitudes of cutting speed. The application of cutting fluid improves surface finish. The specific power consumption decreases with increase in feed values, but shows a rising trend with high values of cutting speed indicative of ineffectiveness of cutting fluid at high speeds.
Influence Of Machining Parameter On Cutting Force And Surface Roughness While Turning Alloy Steel
Materials Today: Proceedings, 2018
Alloy steels are preferred for manufacturing of machine parts owing to their physical and mechanical properties. However, these parts require turning operation to be carried out in order to obtain desired quality product. Components can be machined at minimum lead time, with higher machining parameters such as cutting speed, feed/revolution and depth of cut, which leads to increase in cutting force and surface roughness. Thus, the main objective of present research work is to study the influence of machining parameters on cutting force and surface roughness while machining alloy steels following ISO3685 standards. The experimental results revealed that the surface roughness was low at 350m/min cutting speed and 0.15mm/revolution feed. The cutting forces measured around 35% greater while machining HCHCr alloy steel when compared to EN24 grade alloy steel.
Sinergi, 2020
In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.
Indian Journal of Engineering and Materials Sciences, 2014
In this study, the effects of workpiece hardness, drill diameter, drill length and drilling parameters on thrust force and cutting torque are investigated in the drilling of AISI D2 and AISI D3 cold work tool steels under dry drilling conditions. The experiments are performed at three cutting speeds (5, 10 and 15 m/min) and three feed rates (0.04, 0.05 and 0.06 mm/rev). Workpiece hardness, drill diameter, drill length, cutting speed are considered as independent variables (machining parameters), and full factorial design is selected for experimental trials. Analysis of variance (ANOVA) is employed to determine the most significant machining parameters on the thrust force and cutting torque. The predictive equations are developed in confidence intervals with the linear regression analysis to obtain the thrust force and cutting torque as a function of machining parameters and the correlation coefficients (R 2 ) of equations for thrust force and cutting torque are calculated as 92.7% and 84.1%, respectively. As a result of this study, it is found that all of the machining parameters are effective on the thrust force and cutting torque. Thrust force and cutting torque increase with the increase of workpiece material hardness, drill diameter, drill length, feed rate and number of holes, and decrease with the increase of cutting speed.
Study and Analysis of Effect of Cutting Parameters on Cutting Forces and Surface Roughness
2015
In the present competitive and dynamic market environment, large and small manufacturing industries are more allotted to Optimization and economic machining. Cutting parameters play a crucial role in every machining process in affecting the production rate, quality of the output and economical aspects of a machining process. Finite element simulation of the cutting process is advantageous in many ways over experimental analysis, as it provides information on deformations along each point of cutting line, stresses induced at each node/point and temperature distribution in the tool and work material during the machining process. In this paper, the significant effect of cutting speed, feed rate and rake angle on cutting forces, tool temperature and work specimen temperature in machining AISI 1045 mild carbon steel has been studied. For the study of which, a series of 20 experiments and simulation trials were conducted as per design of experiments. All the other parameters besides the s...
Materials Today: Proceedings, 2020
The machining efficiency and tool life is greatly influenced by the cutting forces generated. As a machining operation is a complex process, it is important to have a thorough idea about the parameters affecting the machining quality. The fine machining quality of the dies produced will be efficacious in the production lines and will also ensure the quality of the product being produced. One such material widely used as hot working dies and casting dies is AISI H13 steel. Thus, this study focuses on investigation of the effects of cutting speed, feed rate and depth of cut on the cutting force components produced during the hard finish turning of heat treated AISI H13 steel using uncoated brazed tungsten carbide tip as the cutting tool material. Initially, annealed H13 steel was hardened and tempered (54 HRC) at specified temperature. Taguchi's L-25 orthogonal array comprising of 3 factors and 5 levels of each was employed for minimizing the cutting forces generated during machining, with the help of signal to noise ratio evaluation. Analysis of variance (ANOVA) study showed that the effect of feed rate and depth of cut on the cutting forces generated are statistically significant in comparison to cutting speed. Additionally, artificial neural network (ANN) models were developed which depicted promising predicting capabilities for determining the cutting forces at any cutting conditions.
Influence of the tool edge geometry on specific cutting energy at high-speed cutting
Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2007
This paper presents specific cutting energy measurements as a function of the cutting speed and tool cutting edge geometry. The experimental work was carried out on a vertical CNC machining center with 7,500 rpm spindle rotation and 7.5 kW power. Hardened steels ASTM H13 (50 HRC) were machined at conventional cutting speed and high-speed cutting (HSC). TiN coated carbides with seven different geometries of chip breaker were applied on dry tests. A special milling tool holder with only one cutting edge was developed and the machining forces needed to calculate the specific cutting energy were recorded using a piezoelectric 4-component dynamometer. Workpiece roughness and chip formation process were also evaluated. The results showed that the specific cutting energy decreased 15.5% when cutting speed was increased up to 700%. An increase of 1° in tool chip breaker chamfer angle lead to a reduction in the specific cutting energy about 13.7% and 28.6% when machining at HSC and conventional cutting speed respectively. Furthermore the workpiece roughness values evaluated in all test conditions were very low, closer to those of typical grinding operations (~0.20 µm). Probable adiabatic shear occurred on chip segmentation at HSC.
Journal of Materials Processing Technology, 2008
In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on cutting forces (feed force, thrust force and cutting force) and surface roughness in finish hard turning of MDN250 steel (equivalent to 18Ni(250) maraging steel) using coated ceramic tool. The machining experiments were conducted based on response surface methodology (RSM) and sequential approach using face centered central composite design. The results show that cutting forces and surface roughness do not vary much with experimental cutting speed in the range of 55-93 m/min. A linear model best fits the variation of cutting forces with feed rate and depth of cut. Depth of cut is the dominant contributor to the feed force, accounting for 89.05% of the feed force whereas feed rate accounts for 6.61% of the feed force. In the thrust force, feed rate and depth of cut contribute 46.71% and 49.59%, respectively. In the cutting force, feed rate and depth of cut contribute 52.60% and 41.63% respectively, plus interaction effect between feed rate and depth of cut provides secondary contribution of 3.85%. A non-linear quadratic model best describes the variation of surface roughness with major contribution of feed rate and secondary contributions of interaction effect between feed rate and depth of cut, secondorder (quadratic) effect of feed rate and interaction effect between speed and depth of cut. The suggested models of cutting forces and surface roughness adequately map within the limits of the cutting parameters considered.