scholarly journals Turning operation of AISI 4340 steel in flooded, near-dry and dry conditions: a comparative study on tool-work interface temperature

2019 ◽  
Vol 23 (1) ◽  
pp. 172-182 ◽  
Author(s):  
Milon Selvam Dennison ◽  
Sivaram N M ◽  
Debabrata Barik ◽  
Senthil Ponnusamy
Keyword(s):  
Cutting Tool ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Velocity ◽  
Dry Conditions ◽  
Cylindrical Steel ◽  
Coated Carbide ◽  
Full Factorial ◽  
Aisi 4340

Abstract The objective of this study is to analyse the effect of tool-work interface temperature observed during the turning of AISI 4340 cylindrical steel components in three machining conditions, namely flooded, near-dry and dry conditions with three separate CNMG-PEF 800 diamond finish Titanium Nitride (TiN) coated carbide cutting tool. The machining parameters considered in this study are cutting velocity, feed rate and depth of cut. The experiments were planned based on full factorial design (33) and executed in an All Geared Conventional Lathe. The tool-work interface temperature was observed using a K-type tool-work thermocouple, while the machining of steel, and subsequently, a mathematical model was developed for the tool-work interface temperature values through regression analysis. The significance of the selected machining parameters and their levels on tool-work interface temperature was found using analysis of variance (ANOVA) and F-test. The results revealed that machining under near-dry condition exhibited lesser temperature at the tool-work interface, which is the sign of producing better quality products in equivalence with the machining under flooded condition.

scholarly journals Multiple Regression Prediction Model for Cutting Forces in Turning Carbon-Reinforced PEEK CF30

2010 ◽  
Vol 2010 ◽  
pp. 1-7 ◽  
Author(s):  
Francisco Mata ◽  
Elena Beamud ◽  
Issam Hanafi ◽  
Abdellatif Khamlichi ◽  
Abdallah Jabbouri ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Quadratic Regression ◽  
Turning Operations ◽  
Dry Conditions ◽  
Full Factorial

Among the thermoplastic polymers available, the reinforced polyetheretherketone with 30% of carbon fibres (PEEK CF 30) demonstrates a particularly good combination of strength, rigidity, and hardness, which prove ideal for industrial applications. Considering these properties and potential areas of application, it is necessary to investigate the machining of PEEK CF30. In this study, response surface methodology was applied to predict the cutting forces in turning operations using TiN-coated cutting tools under dry conditions where the machining parameters are cutting speed ranges, feed rate, and depth of cut. For this study, the experiments have been conducted using full factorial design in the design of experiments (DOEs) on CNC turning machine. Based on statistical analysis, multiple quadratic regression model for cutting forces was derived with satisfactory -squared correlation. This model proved to be highly preferment for predicting cutting forces.

scholarly journals Wear Mechanism of Multilayer Coated Carbide Cutting Tool in the Milling Process of AISI 4340 under Cryogenic Environment

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 524
Author(s):  
Shalina Sheik Muhamad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Hafizal Yazid
Keyword(s):  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Tool ◽  
Milling Process ◽  
Machining Parameters ◽  
Rake Face ◽  
Crater Wear ◽  
Carbide Cutting Tool ◽  
Coated Carbide ◽  
Aisi 4340

Cryogenic technique is the use of a cryogenic medium as a coolant in machining operations. Commonly used cryogens are liquid nitrogen (LN2) and carbon dioxide (CO2) because of their low cost and non-harmful environmental impact. In this study, the effects of machining conditions and parameters on the wear mechanism were analysed in the milling process of AISI 4340 steel (32 HRC) under cryogenic conditions using a multilayer coated carbide cutting tool (TiAlN/AlCrN). A field emission scanning electron microscope with energy-dispersive X-ray analysis was used to examine the wear mechanisms comprehensively. At low machining parameters, abrasion and adhesion were the major wear mechanisms which occurred on the rake face. Machining at high machining parameters caused the removal of the coating material on the rake face due to the high temperature and cutting force generated during the cutting process. In addition, it was found that continuously adhered material on the rake face would lead to crater wear. Furthermore, the phenomenon of oxidation was also observed when machining at high cutting speed, which resulted in diffusion wear and increase in the crater wear. Based on the relationship between the cutting force and cutting temperature, it can be concluded that these machining outputs are significant in affecting the progression of tool wear rate, and tool wear mechanism in the machining of AISI 4340 alloy steel.

scholarly journals Cryogenic milling and formation of nanostructured machined surface of AISI 4340

2020 ◽  
Vol 9 (1) ◽  
pp. 1104-1117
Author(s):  
Shalina Sheik Muhamad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Hafizal Yazid
Keyword(s):  
End Milling ◽  
Testing Machine ◽  
Machining Process ◽  
Depth Of Cut ◽  
Case Hardening ◽  
Machining Parameters ◽  
Machined Surface ◽  
Radial Depth ◽  
Coated Carbide ◽  
Aisi 4340

AbstractHardened layers are commonly required for automotive components after their production using a machining process in order to enhance the service life of these components. This study investigates the possibility of producing a nanostructured machined surface which can increase the hardness of the machined surface by varying the machining parameters under cryogenic conditions in end milling of AISI 4340. The end milling experiments were performed using multi-layered TiAlN- and AlCrN-coated carbide. Prior to the experiment, a finite element method (FEM) was used to simulate the cutting temperature generated and it had been found that at cutting speed of 200–300 m/min, feed rate of 0.15–0.3 mm/tooth, axial depth of cut of 0.3–0.5 mm, and radial depth of cut of 0.2–0.35 mm, the temperature generated can be sufficiently high to cause austenitic transformation. A field emission scanning electron microscope (FESEM) equipped with angle selective backscattered (AsB) detection analysis was used to investigate the microstructure and machined-affected layers of the machined surfaces. The crystallographic orientation/phase change and nano-hardness were analysed through X-ray diffraction (XRD) and a nano-hardness testing machine. The results showed that the cryogenic machining had significantly affected the surface integrity characteristics of the AISI 4340 alloy due to refined microstructure, favourable phase structure, and higher hardness near the surface layer. The results of this study may be useful in providing an insight into a potential technological shift from conventional surface case hardening processes to the present technique.

Investigation of Chip-Tool Interface Temperature during Turning of Hardened AISI 4340 Alloy Steel Using Multi-Layer Coated Carbide Inserts

2013 ◽  
Vol 701 ◽  
pp. 354-358 ◽  
Author(s):  
Satish Chinchanikar ◽  
S. K. Choudhury ◽  
A. P. Kulkarni
Keyword(s):  
Cutting Speed ◽  
Cutting Parameters ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Work Material ◽  
Predicted Values ◽  
On Chip ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Aisi 4340

In the present work, effect of work material hardness and cutting parameters on chip-tool interface temperature was investigated during turning of AISI 4340 steel hardened at two different levels of hardness 35 and 45 HRC, respectively, using CVD applied multi-layer TiCN/Al2O3/TiN coated carbide inserts. A tool-work thermocouple principle was used to measure the interface temperature during turning. The correlation coefficient between experimental and predicted values of interface temperature found close to 0.95, which showed that the developed model is reliable and could be used effectively for predicting the interface temperature for the given tool and work material pair and within the domain of the cutting parameters. Experimental observations indicate that the interface temperature is higher for harder work material and get affected mostly by cutting speed followed by feed. However, depth of cut has little influence on interface temperature irrespective of the hardness of the workpiece.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

An investigation on formation of burrs during milling of aluminium alloy under wet condition

2020 ◽  
pp. 095440542097201
Author(s):  
Raj Sekhar Mandal ◽  
Santanu Das ◽  
Partha Pratim Saha
Keyword(s):  
Suitable Condition ◽  
Face Milling ◽  
Machining Process ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Burr Height ◽  
Cutting Velocity ◽  
Wet Condition ◽  
Exit Edge ◽  
Coated Carbide

Undesirable burrs are created out of a machining process. The objective of the present work is to explore the suitable condition to obtain no burr, or negligible burr, around the edge of a machined product at wet condition. Face milling experiments have been carried out on blocks made of aluminum alloy (Alloy-4600M) with a single, coated-carbide inserted cutter for observing the nature of burr formation. Depth of cut has been maintained constant at 3 mm for all sets of experiments. In each experiment set, three cutting velocities (170 m/min, 237 m/min and 339 m/min) and three in-plane exit angles of 30°, 60° and 90° are provided at three different feeds of 0.08 mm/tooth, 0.1 mm/tooth and 0.12 mm/tooth. First set of experiments are done without any exit edge bevel. Similar sets of experiments are carried out with 15° and 30° exit edge bevel angles to find out the condition for minimum burr. The bevel is made of a height of 3 mm. In the present experimental investigation, a minimum burr height of as low as 3 micron is obtained at an in-plane exit angle of 30° and exit edge bevel angle of 15° under the machining condition of 339 m/min cutting velocity and 0.1 mm/tooth feed.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Investigation on Surface Roughness and Cutting Temperature in Turning AISI 316 Austenitic Stainless Steel Using TiAlSiN Coated Carbide Insert

2013 ◽  
Vol 446-447 ◽  
pp. 291-295
Author(s):  
Malhar Ozarkar ◽  
Rugwed Bhatkhande ◽  
Shray Jerath ◽  
A.P. Kulkarni
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Experimental Result ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Aisi 316 ◽  
Coated Carbide ◽  
Coated Cemented Carbide ◽  
Carbide Insert ◽  
Tialsin Coating

This study presents experimental result of surface roughness and chip-tool interface temperature developed during turning of AISI 316 austenitic stainless steels using TiAlSiN coated cemented carbide insert. TiAlSiN coating is deposited by Cathodic Arc Evaporation (PVD) technique. The work-tool thermocouple calibration set-up was developed. The air heater was used as a heating element at the work-tool junction. The experiments were conducted at cutting speeds in the range of 140 to 320 m/min, feed in the range of 0.08 to 0.26 mm/rev keeping depth of cut constant at 1 mm. The influence of cutting parameters and tool coating were investigated on the average chip-tool interface temperature and surface roughness. Experimentally interface temperature 979°C was observed at 260 m/min cutting speed and 0.14 mm/rev feed. The interface temperature in turning is strongly dependent on the cutting speed followed by feed and exactly reverse case was observed in case of surface roughness. TiAlSiN coating shows better performance and can be considered as a prominent candidate for the machining of AISI 316 work material.

Modeling the Force, Surface Roughness and Cutting Temperature in Ultrasonic Vibration-Assisted Turning of Al7075

2009 ◽  
Vol 83-86 ◽  
pp. 315-325 ◽  
Author(s):  
Mohammad Javad Nategh ◽  
Saeed Amini ◽  
H. Soleimanimehr
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Ultrasonic Frequency ◽  
Factorial Experiments ◽  
Machining Force ◽  
Cutting Velocity ◽  
Full Factorial

The single point cutting tool in ultrasonic vibration-assisted turning (UAT) is made to vibrate under ultrasonic frequency. In present study, the influence of various parameters such as vibration amplitude, depth of cut, feed rate and cutting velocity on the machining force and workpiece's surface roughness in UAT of Al7075 has been investigated. Full factorial experiments were carried out with an ultrasonic frequency range of 20±0.5 kHz. ANOVA was conducted on the experimental results and regression models were obtained for predicting the machining force, surface roughness and cutting temperature. The proposed models were verified by further experiments. The robustness of the proposed models was then investigated whence the optimal parameters were estimated. Similar full factorial experiments were also carried out with conventional turning (CT) in order to compare the results with those of UAT.

Evolutionary Computation in Combinatorial of Machining Parameters of Reinforced PEEK Composites Using NSGA-II

2014 ◽  
Vol 875-877 ◽  
pp. 652-656
Author(s):  
Issam Hanafi ◽  
Khamlichi Abdellatif ◽  
Francisco Mata Cabrera
Keyword(s):  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Nsga Ii ◽  
Coated Tools ◽  
Machining Force ◽  
High Feed ◽  
Dry Conditions ◽  
Main Operating

The machining parameters for turning of PEEK CF30 using TiN coated tools under dry conditions have been optimized by using Non dominated Sorting Genetic Algorithm (NSGA-II), a non dominated solution set is obtained. The objectives considered are the minimisation of machining force thereby minimising specific cutting pressure as function of the main operating parameters. The results indicated that the minimal cutting parameters are preferred for reducing the machining force, and the minimal cutting speed, medium depth of cut and high feed rate are recommended for minimal specific cutting machining. As per the requirement, the manufacturing engineer should select the proper cutting parameters.

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