Effects of Liquid Nitrogen on Cryogenic Machining of Aisi D2 Hardened Steel

2011 ◽  
Vol 335-336 ◽  
pp. 400-405
Author(s):  
Samraj Ravi ◽  
Murugasan Pradeep Kumar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Liquid Nitrogen ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Cryogenic Machining ◽  
Workpiece Surface ◽  
Aisi D2 ◽  
Cutting Zone ◽  
Coated Carbide

The milling of hardened steel generates very high temperature in the cutting zone, and leads to detrimental effects on the cutting force, workpiece surface finish and tool life. Cryogenic machining is an environmental friendly new approach for the desirable control of the cutting temperature in the cutting zone. The present work investigates the effect of cryogenic cooling by liquid nitrogen (LN2) on the cutting temperature, cutting force and workpiece surface roughness on the end milling of AISI D2 steel by CVD TiN coated carbide insert, at a constant cutting speed of 100 m/min and varying feed rate in the range of 0.01-0.02 mm/tooth. The experimental results showed that with LN2 as a coolant the cutting force and workpiece surface roughness were reduced compared to dry and wet machining due to the better lubrication and cooling effect through reduction of cutting zone temperature.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

Performance Evaluation of Liquid Nitrogen as Coolant in Turning of Al/SiC Metal Matrix Composites (AMMC)

2014 ◽  
Vol 893 ◽  
pp. 341-345 ◽  
Author(s):  
Vadivel Muthuraman ◽  
Murugesan Pradeepkumar
Keyword(s):  
Cutting Force ◽  
Liquid Nitrogen ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cryogenic Liquid ◽  
Matrix Composites ◽  
Performance Parameters ◽  
Cryogenic Machining ◽  
Machining Performance ◽  
Better Than

This paper presents the results of an experimental investigation on the turning of Al/SiC (LM-13) composite using Cryogenic Liquid Nitrogen (LN2) as coolant. The influence of machining performance parameters such as cutting force, cutting temperature and surface finish were investigated under wet and cryogenic machining. The results proved that the application of cryogenic LN2coolant reduced the cutting temperature and the cutting force for about 19 to 30% and 24 to 35% respectively. The surface finish of the machined part is about 10 to 23% better than in the conventional coolant. Thus it was proved that the application of cryogenic coolants reduced the cutting force and temperature which resulted in an appreciable improvement in surface finish in machining of Al/SiC MMC.

Investigation of Tool Wear, Tool Life and Surface Roughness when Machining AISI D2 Hardened Steel Using PVD TiAlN Coated Carbide Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1098-1102 ◽  
Author(s):  
Noor Hakim Rafai ◽  
Mohd Amri Lajis ◽  
N.A.J. Hosni
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Material Removal ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Tool Failure ◽  
Aisi D2 ◽  
Wear Tool ◽  
Coated Carbide

This paper discussed the behavior of cutting tool in terms of tool wear, tool life and surface roughness when machining an AISI D2 hardened steel. An experimental test was conducted at different cutting speeds (Vc) and radial depth of cut (ae) using PVD TiAlN coated carbide tool under dry condition. Tool failure modes and tool wear mechanism for all cutting tools were examined at various cutting parameters. Flank wear was found to be the predominant tool failure for cutting tools. The highest volume material removal (VMR) attained was 3750 mm3 meanwhile the highest tool life (TL) was 9.69 min. The surface roughness (Ra) values from 0.09 to 0.24 μm can be attained in the workpiece with a high material removal. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high material removal, maximum tool life as well as acceptable surface finish.

The Machinability Evaluation of Hardened Steel 7CrSiMnMoV

2016 ◽  
Vol 836-837 ◽  
pp. 64-70
Author(s):  
Xin Min Feng ◽  
S.M. Zhang ◽  
J.S. Hu ◽  
X. Song ◽  
F. Liu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Evaluation Model ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Machining Process ◽  
Evaluation Index ◽  
Fuzzy Synthetic Evaluation ◽  
Technological Parameters ◽  
Synthetic Evaluation

Based on the cutting performance parameter of hardened steel 7CrSiMnMoV and the application of fuzzy synthetic evaluation principle, the essay establishes a two-level fuzzy synthetic evaluation model of the machinability of 7CrSiMnMoV. Choosing cutting force, cutting temperature and surface roughness of the workpiece produced during machining process as the evaluation index, data are measured through experiment and a synthetic evaluation of the machinability of hardened steel 7CrSiMnMoV is conducted. The result shows that it is reasonable to use cutting force, cutting temperature and surface roughness of the workpiece as evaluation index to evaluate the material machinability. And it also provides guidance to the selection of tools and the technological parameters during the process of cutting 7CrSiMnMoV.

Tribological Characterization of the Cutting Zone in Milling Nickel Based Alloy

2014 ◽  
Vol 554 ◽  
pp. 12-16 ◽  
Author(s):  
Musfirah Abdul Hadi ◽  
Jaharah A. Ghani ◽  
C.H. Che Haron ◽  
Natasha A. Raof
Keyword(s):  
Surface Roughness ◽  
Physical Vapor Deposition ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Cutting Zone ◽  
Tribological Characterization ◽  
Coated Carbide

In the area of tribology, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in milling process. Experiments were performed using physical vapor deposition (PVD) - coated carbide inserts under cryogenic and dry cutting condition. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining.

Prediction of Surface Roughness on CNC Turning Based on Monitoring of Cutting Force and Cutting Temperature

2013 ◽  
Vol 690-693 ◽  
pp. 2540-2549 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Cnc Turning ◽  
Roughness Model ◽  
Developed Surface ◽  
Coated Carbide

This paper presents the surface roughness model which is proposed and developed to predict the surface roughness in the CNC turning of the carbon steel with the coated carbide tool under various cutting conditions by using the response surface analysis with the Box-Behnken design based on the experimental results. The in-process monitoring of the cutting force and the cutting temperature is utilized to analyze the relation between the surface roughness and the cutting condition. The tool dynamometer and the infrared pyrometer are employed and installed on the turret of CNC turning machine to measure the in-process cutting force and cutting temperature. The models of cutting force ratio and cutting temperature are also developed based on the experimental data. The optimum cutting condition is determined referring to the minimum surface roughness of the surface plot, which is obtained from the developed surface roughness model. The experimental results show that the higher cutting speed gives the better surface roughness due to the higher cutting temperature, however the tool life becomes shorter. The feed rate is the most significant factor which affects the surface roughness, while a small depth of cut helps to improve the surface roughness. The effectiveness of the surface roughness prediction model has been proved by utilizing an analysis of variance (ANOVA) at 95% confident level. Hence, the surface roughness can be predicted and obtained easily referring to the developed surface roughness model.

Development of Surface Roughness Prediction for Steel in CNC Turning by Using Response Surface Method

2011 ◽  
Vol 335-336 ◽  
pp. 921-926
Author(s):  
Siriwan Chanphong ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Plain Carbon Steel ◽  
Cutting Condition ◽  
Surface Roughness Prediction ◽  
Roughness Prediction ◽  
Coated Carbide

This research presents the development of the surface roughness prediction in the turning process of the plain carbon steel with the coated carbide tool by using the response surface analysis with the Box-Behnken design. The effects of cutting parameters on the cutting force and the cutting temperature are investigated. The cutting force and the cutting temperature are measured to help analyze the relation between the surface roughness and the cutting conditions. The models of cutting force ratio and the cutting temperature are also proposed based on the experimental data. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Study on the effect of semisolid lubricants on tribological properties of hardened steel during boring process

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Lawrance G. ◽  
P. Sam Paul ◽  
Varadarajan A.S.
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Tribological Properties ◽  
Cutting Temperature ◽  
Aluminium Oxide ◽  
Cutting Fluids ◽  
Tool Vibration ◽  
Content Type ◽  
Vibration Cutting ◽  
Cutting Zone

Purpose In the internal turning process, tool life and work piece quality are greatly influenced by the generation of heat in the cutting zone. During machining, cutting fluids are applied at the cutting zones to reduce heat generation and enhance tribological properties. However, in the boring process, cutting fluids cannot be applied at cutting zone properly, and wastage of cutting fluid is a threat to the ecology and personnel health. Hence, application of semisolid lubricant in the boring process is considered as an innovative technique for temperature reduction in cutting zone because of its eco-friendly system, which also has a higher ability of biodegradability. This paper aims to study the influence of semisolid lubricants comprising of grease,graphite, aluminium oxide in different composition applied at a tool–chip,tool–work interface using a semisolid lubricant applicator applied with varying pressure. Design/methodology/approach In the present study, the cutting performance during boring of AISI4340 steel is enhanced through the application of semisolid lubricant with different composition of grease, graphite and aluminium oxide applied at tool-work and tool-chip interface with varying pressure using semisolid lubricant applicator. Findings The results show that use of semisolid lubricant like grease, graphite and nano aluminium oxide at tool-chip interface with maximum pressure reduces cutting temperature, tool vibration, cutting force and surface roughness. Originality/value Reduce cutting temperature, tool vibration, cutting force and surface roughness.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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