Investigation on turning of AISI 1040 steel with the application of nano-crystalline graphite powder as lubricant

2013 ◽  
Vol 228 (9) ◽  
pp. 1570-1580 ◽  
Author(s):  
S Srikiran ◽  
K Ramji ◽  
B Satyanarayana ◽  
SV Ramana
Keyword(s):  
Heat Generation ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Graphite Powder ◽  
Chemical Degradation ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Feed Force ◽  
Particulate Solid ◽  
Cutting Zone

The past few decades have witnessed significant advancements in turning processes, cutting tools and coolant/lubricant chemistry. These developments have enhanced the machining capabilities of hard materials when machining at higher cutting conditions. Turning, being characterized by the development of high temperatures at the cutting zone, is critical with respect to the tool life and surface finish apart from other machining results like the forces generated. This phenomenon of heat generation at the cutting zone plays a negative role during turning operations due to their peculiar characteristics such as poor thermal conductivity, high strength at elevated temperature, resistance to wear and chemical degradation. Cutting fluids and solid lubricants are generally used to overcome the problem of heat generation at the cutting zone. The use of cutting fluids in the conventional way may not effectively control the heat generated in turning operation. Moreover, cutting fluids are a major source of pollution. With the advancement in technology, nano-level particulate solid lubricants are being used nowadays in machining operations, especially grinding and turning. The present work deals with the investigation of using nano-level particulate graphite powder as a solid lubricant and various tests were conducted by machining AISI 1040 steel using tungsten carbide inserts. The experiments were conducted by taking into account the parameters like feed rate ranging from 0.05 mm/rev to 0.125 mm/rev, cutting speed ranging from 51 m/min to 192.6 m/min and depth of cut from 0.25 mm to 1 mm. Four levels of each parameter are considered for experimentation. The results indicate that with the decrease in the nano-sized graphite powder, there is an increase of cutting forces – feed force, cutting force and thrust force. The temperatures at the tool–chip interface also increases with the decrease in the lubricant size. It is found that the surface roughness of the workpiece after machining deteriorated due to the size of the lubricant particle.

scholarly journals Internally cooled tools and cutting temperature in contamination-free machining

2013 ◽  
Vol 228 (1) ◽  
pp. 135-145 ◽  
Author(s):  
Carlo Ferri ◽  
Timothy Minton ◽  
Saiful Bin Che Ghani ◽  
Kai Cheng
Keyword(s):  
Heat Generation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Rake Face ◽  
Metal Working ◽  
Chip Temperature ◽  
Internally Cooled ◽  
Cutting Zone ◽  
And Diffusion

Whilst machining heat is generated by the friction inherent into the sliding of the chip on the rake face of the insert, the temperature in the cutting zone of both the insert and the chip rises, facilitating adhesion and diffusion. These effects accelerate the insert wear, ultimately undermining the tool life. Therefore, a number of methods have been developed to control the heat generation. Most typically, metal working fluids are conveyed onto the rake face in the cutting zone, with negative implications on the contamination of the part. Many applications for instance in health care and optics are often hindered by this contamination. In this study, microfluidics structures internal to the insert were examined as a means of controlling the heat generation. Conventional and internally cooled tools were compared in dry turning of AA6082-T6 aluminium alloy in two 33 factorial experiments of different machining conditions. Statistical analyses supported the conclusion that the chip temperature depends only on the depth of cut but not on the feed rate or on the cutting speed. They also showed that the benefit of cooling the insert internally increases while increasing the depth of cut. Internally cooled tools can therefore be particularly advantageous in roughing operations.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Multi-criteria optimization and predictive modeling of turning forces in high-speed machining of yttria based zirconia toughened alumina insert using desirability function approach

2015 ◽  
Vol 231 (8) ◽  
pp. 1396-1408 ◽  
Author(s):  
Nilrudra Mandal ◽  
B Doloi ◽  
Biswanath Mondal ◽  
BK Singh
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Forces ◽  
Feed Force ◽  
Response Optimization ◽  
Zirconia Toughened Alumina

An attempt has been made to apply the Taguchi parameter design method and multi-response optimization using desirability analysis for optimizing the cutting conditions (cutting speed, feed rate and depth of cut) on machining forces while finish turning of AISI 4340 steel using developed yttria based zirconia toughened alumina inserts. These zirconia toughened alumina inserts were prepared through wet chemical co-precipitation route followed by powder metallurgy process. The L9 (4) orthogonal array of the Taguchi experiment is selected for three major parameters, and based on the mean response and signal-to-noise ratio of measured machining forces, the optimal cutting condition arrived for feed force is A1, B1 and C3 (cutting speed: 150 m/min, depth of cut: 0.5 mm and feed rate: 0.28 mm/rev) and for thrust and cutting forces is A3, B1 and C1 (cutting speed: 350 m/min, depth of cut: 0.5 mm and feed rate: 0.18 mm/rev) considering the smaller-the-better approach. Multi-response optimization using desirability function has been applied to minimize each response, that is, machining forces, simultaneously by setting a goal of highest cutting speed and feed rate criteria. From this study, it can be concluded that the optimum parameters can be set at cutting speed of 350 m/min, depth of cut of 0.5 mm and feed rate of 0.25 mm/rev for minimizing the forces with 78% desirability level.

Performance Profiling of Nanoparticulate Graphite Powder as Lubricant in the Machining of AISI 1040 Steel under Variable Machining Conditions

2014 ◽  
Vol 984-985 ◽  
pp. 15-24 ◽  
Author(s):  
S. Srikiran ◽  
K. Ramji ◽  
B. Satyanarayana
Keyword(s):  
Particle Size ◽  
Surface Finish ◽  
Cutting Forces ◽  
Solid Lubricant ◽  
Graphite Powder ◽  
Nano Particles ◽  
Chemical Degradation ◽  
Work Piece ◽  
Tool Temperature ◽  
Cutting Zone

The generation of heat during machining at the cutting zone adversely affects the surface finish and tool life. The heat at the cutting zone, which plays a negative role due to poor thermal conductivity, resistance to wear, high strength at high temperatures and chemical degradation can be overcome by the use of proper lubrication. Advancements in the field of tribology have led to the use of solid lubricants replacing the conventional flood coolants. This work involves the use of nanoparticulate graphite powder as a lubricant in turning operations whose performance is judged in terms of cutting forces, tool temperature and surface finish of the work piece. The experimentation revealed the increase in cutting forces and the tool temperature when the solid lubricant used is decreased in particle size. The surface finish deteriorated with the decrease in particle size of the lubricant in the nanoregime.Keywords-Turning, Solid lubricant, Graphite, Minimum Quantity Lubrication, nano–particles,Weight percentage,Frictioncoefficient.

Manufacturing Accuracy when Drilling Holes in Stainless Austenitic Steels DIN 1.4301

2013 ◽  
Vol 420 ◽  
pp. 250-253 ◽  
Author(s):  
Jozef Jurko
Keyword(s):  
Stainless Steels ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Austenitic Steels ◽  
Depth Of Cut ◽  
Surface Accuracy ◽  
Cutting Zone ◽  
Manufacturing Accuracy

This article presents the results of experiments that concerned on the surface accuracy by drilling of a Stainless steels 1.4301. This article presents conclusions of machinability tests on a Stainless steels 1.4301. The results of cutting zone evaluation under cutting conditions (cutting speed in interval vc=50-100 m/min, depth of cut ap=2.75 mm and feed f=0.01-0,8 mm per rev.).

Performance Investigation of Modified Turning Tool Holder for MQL Application

2013 ◽  
Vol 465-466 ◽  
pp. 1114-1118
Author(s):  
Erween Abdul Rahim ◽  
Z.H. Samsudin ◽  
Muhammad Arif Abdul Rahim ◽  
Zazuli Mohid
Keyword(s):  
Single Channel ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Tool Holder ◽  
Dual Channel ◽  
Minimal Quantity Lubrication ◽  
Cutting Zone

Some machining process requires coolant to reduce the cutting temperature and helps to flush away the chips from the cutting zone. However, conventional flood coolant possesses some issues towards workers and the environment, regarding health and waste management. The implementation of Minimal Quantity Lubrication (MQL) as an alternative technique seems to be promising although the effectiveness of this technique were influenced by several factor. In turning process for instance, the distance of nozzle to the cutting zone contributes to the variation of machining performance. This study is to compare the effect on cutting performance between two internal MQL nozzle designs. The cutting tool holder were modified to have two internal MQL oil channel. The oil channel design were tested and the performance was evaluated in terms of cutting speed and cutting temperature for different cutting speed, feed rate and depth of cut. The result shows that the single channel performs better in terms of cutting force while dual channel significantly improve the cutting temperature.

scholarly journals Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

2021 ◽  
Vol 27 (4) ◽  
pp. 296-305
Author(s):  
Arpit Srivastava ◽  
Mukesh Kumar Verma ◽  
Ramendra Singh Niranjan ◽  
Abhishek Chandra ◽  
Praveen Bhai Patel
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Cutting Speed ◽  
Radial Force ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimization Of Process Parameters ◽  
Feed Force ◽  
Aluminum 7075 ◽  
Aluminum Alloy 7075

Abstract Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain signifi-cant factors and optimal combinations of process parameters.

scholarly journals Neural Network Modeling of Cutting Force and Chip Thickness Ratio for Turning Aluminum Alloy 7075-T6

2018 ◽  
Vol 14 (1) ◽  
pp. 67-76
Author(s):  
Mohanned Mohammed H. AL-Khafaji
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Thickness Ratio ◽  
Depth Of Cut ◽  
Feed Force ◽  
Machining Force ◽  
Force Components

The turning process has various factors, which affecting machinability and should be investigated. These are surface roughness, tool life, power consumption, cutting temperature, machining force components, tool wear, and chip thickness ratio. These factors made the process nonlinear and complicated. This work aims to build neural network models to correlate the cutting parameters, namely cutting speed, depth of cut and feed rate, to the machining force and chip thickness ratio. The turning process was performed on high strength aluminum alloy 7075-T6. Three radial basis neural networks are constructed for cutting force, passive force, and feed force. In addition, a radial basis network is constructed to model the chip thickness ratio. The inputs to all networks are cutting speed, depth of cut, and feed rate. All networks performances (outputs) for all machining force components (cutting force, passive force and feed force) showed perfect match with the experimental data and the calculated correlation coefficients were equal to one. The built network for the chip thickness ratio is giving correlation coefficient equal one too, when its output compared with the experimental results. These networks (models) are used to optimize the cutting parameters that produce the lowest machining force and chip thickness ratio. The models showed that the optimum machining force was (240.46 N) which can be produced when the cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.27 mm/rev). The proposed network for the chip thickness ratio showed that the minimum chip thickness is (1.21), which is at cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.17 mm/rev).

Optimizing Feed Force in Turning Process Using Taguchi’s Parameter Design Approach

2014 ◽  
Vol 592-594 ◽  
pp. 668-672
Author(s):  
Praveen Kumar ◽  
Hari Singh
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Cutting Speed ◽  
Design Approach ◽  
Parameter Design ◽  
Depth Of Cut ◽  
Turning Process ◽  
Feed Force ◽  
Optimal Value ◽  
Optimal Setting

The objective of the paper is to obtain an optimal setting of turning process parameters (cutting speed, depth of cut and feed rate) resulting in an optimal value of the feed force when machining En19 steel with tungsten carbide cutting tool inserts. The effects of the selected turning process parameters on feed force and the subsequent optimal settings of the parameters have been accomplished using Taguchi’s parameter design approach. It was indicated by the results that the selected turning process parameters significantly affect the selected machining characteristic. The percent contributions of parameters as quantified in the S/N ANOVA envisage that the relative power of cutting speed (72.09 %) in controlling variation and mean feed force is significantly higher than that of the depth of cut (22.30 %) and feed rate (05.31 %). The predicted optimum feed force is 98.067 N. The results have been validated by the confirmation experiments.

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