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Performance Analysis of Coated Single Point Cutting Tool in Turning Operation

This document summarizes a study that analyzed the performance of single point cutting tools coated with nickel and zinc when used in turning aluminum. The study measured temperature at the chip-tool interface, surface roughness, and material removal rate for different cutting speeds, feed rates, and depths of cut. Twenty-four experiments were conducted using high speed steel tools coated with nickel or zinc and results were compared to uncoated tools. The study found that tool coating improved performance by reducing interface temperature and improving surface finish compared to uncoated tools.

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0% found this document useful (0 votes)
91 views10 pages

Performance Analysis of Coated Single Point Cutting Tool in Turning Operation

This document summarizes a study that analyzed the performance of single point cutting tools coated with nickel and zinc when used in turning aluminum. The study measured temperature at the chip-tool interface, surface roughness, and material removal rate for different cutting speeds, feed rates, and depths of cut. Twenty-four experiments were conducted using high speed steel tools coated with nickel or zinc and results were compared to uncoated tools. The study found that tool coating improved performance by reducing interface temperature and improving surface finish compared to uncoated tools.

Uploaded by

Viraj Gaonkar
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Shreedhar Bhattarai* et al.

(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

Performance Analysis of Coated Single


Point Cutting Tool in Turning Operation
SHREEDHAR B HATTARAI
Graduate Student,
Depart ment of Mechanical Engineering, UCEK (A),
Jawaharlal Nehru Technological Un iversity Kakinada (JNTUK)
Kakinada, East Godavari, Andhra Pradesh, India
Abstract Machining is the heart of any manufacturing i ndustry. From any small electronic component
to heavy and macro size material requires machining for its production. Cutting tool is required for
machining process. Engineers and scientists are working to find out the best techni que for increasing the
efficiency of machining process. The coating of cutting tool is one of the processes to increase the
performance and producti vity in machining process.
The objecti ve of this thesis work is to analyze the performance of single point cutting tool coated wi th
metal (Nickel and Zinc) in the turning operati on of Aluminum. The single poi nt cutting tool is used for
machining cylindrical shaped s peci men of Aluminum. A number of tests are performed wi th different
cutting s peeds, feed rates and depth of cuts. The temperature in the chi p-tool interface and surface
roughness is measured and material removal rate is calculated. These data hel ped i n analyzing the
performance of cutting process.
The tool used is high speed steel and are coated wi th Nickel and Zinc separatel y. Total twenty four
experi ments are carried out and results are tabul ated.
The results obtained from turning operation by coated tools are compared wi th uncoated tool to draw a
vali d conclusion.
Keywords Single Point Cutti ng Tools; Turning Operation; Tool Coating; Chi p-Tool Interface
Temperature; Surface Roughness; Performance analysis of coated tool.
I.

INTRODUCTION

During turning operation the material is removed


fro mworkp iece in the form of chips by the shear
action of cutting tool. The heat is produced because
of shear action as well as because of rubbing of
tool on workp iece and chips on tool. The heat
produced is distributed on tool, chip and
workp iece. The heat generation process greatly
affects the further performance of cutting process.
So Temperature generated in cutting tool-chip
interface is taken as one of the parameter to analyze
the performance.Moreover surface roughness of
mach ined work is another factor which is to be
taken into consideration to do analysis of single
point cutting tool.
Tool coating is done to increase the performance of
single point cutting tool. Most of the researchers
have done experiment using tool coating as
Titaniu m o xide, Titaniu m carb ide, Titaniu m Nitride
using Physical Vapor Deposition (PVD) or
Chemical Vapor Deposition (CVD) methods.
Cutting speed, feed and depth of cut are taken as
input for this experimentation.
II.

LITERATURE REVIEW

Literature has been collected from various journals,


books, papers etc. and has been reviewed as
follows-

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Increasing the productivity and the quality of


the machined parts are the main challenges of
manufacturing
industries.
This
objective
requires better management of the machin ing
system. Th is literature includes information on
temperature in chip-tool interface, surface finish
and material removal rate in turning and coating
materials for cutting tools. Optimization of cutting
parameters is valuable in terms of provid ing
high precision and efficient machin ing. So an
attempt is made to optimize machin ing parameters
using coated tools. The user of the machine tool
must know how to choose cutting parameters in
order to minimize cutting time, cutting force and
produce better surface finish under stable
conditions.
It is necessary for tool materials to possess high
temperature strength. While many ceramic
materials such as TiC, Al2 O3 and TiN possess high
temperature
strength, they have lower fracture
toughness than that of conventional tool materials
such as high-speed steels and cemented tungsten
carbides. The machining of hard and chemically
reactivematerials at higher speeds is improved by
depositing single
and multi-layer coatings on
conventional tool materials to combine the
beneficial properties of ceramics and traditional
tool materials.

@ 2013 http://www.ijitr.co m All rights Reserved.

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Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

J.A. Ghani et al. [1] investigated the wear


mechanis m of TiN-coated carbide and uncoated
cermets tools at various combinations of cutting
speed, feed rate, and depth of cut for hardened AISI
H13 tool steel. They have observed that the time
taken for the cutting edge of TiN-coated carbide
tools to initiate cracking and fracturing is longer
than that of uncoated cermets tools, especially at
the combinations of high cutting speed, feed rate,
and depth of cut and at the combinations of low
cutting speed, feed rate, and depth of cut, the
uncoatedcermets
tools
show
moreuniform
andgradual wear on the flank face than that of the
TiN-coated carbide tools.
Yong Huang et al. [2] have evaluated tool
performance in terms of tool life basedon the flank
wear criterion as a function of cutting conditions,
that is, cutting speed, feed, and depth of cut. They
found out that cutting speed plays a dominant role
in determining the tool performance in terms of
tool life, followed by feed and depth of cut, and
overall tendencies agree with predictions from the
general Taylor tool life equation as well as
experimental observations.
Schulz et al. [3] stated that cutting edges of
cemented carbide tools coated with TiC, TiN or
(Ti, Al)N by chemical vapor deposition (CVD) and
or by physical vapor deposition (PVD) processes
can show an increase of the service lifetime of tools
by a factor of ten compared to uncoated tools.
It is found by F Akbar et al.[4] that the use of TiNcoated tools causes a reduction in heat partition
into the cutting tool compared with the uncoated
tool about 17 percent at conventional cutting speed
and 60 percent in the HSM region.
According to RAMAMOORTHY et al. [5]the
sputter deposition conditions for DLC/TiN/
Ti/Cu/Ni mult ilayer coatings are identified to
achieve improved quality with particular reference
to adhesion and surface finish.
K. Subramanyam et al. [6] studied the performance
of coated tools in machin ing hardening steel under
dry conditions. The experimental results showed
with increase in feed the surface roughness
observed is very poor. The effect of cutting
velocity on surface roughness is relatively low
when compared to feed rate. With increase in depth
of cut the surface roughness is increased. Here
experimental results shows by selecting the proper
cutting parameters the coated tools are suitable to
produce fine surface fin ished components.
As per L.B. Abhang et al. [7] it has been
undertaken into measuring the temperatures
generated during cutting operations. The main
techniques used to evaluate the cutting temperature
during mach ining are tool-chip thermocouple,
embedded thermocouple, and thermal radiat ion

2320 5547

method. Tool-work thermocouple has become a


popular tool to be used in temperature
measurements during metal cutting. In this paper
the tool-work thermo couple technique was used to
measure the chip-tool interface temperature during
mach ining of EN-31 steel alloy.
M.B.Silva and Wall Bank J. [8] stated the
improvement of cutting performance, the
knowledge of temperature at the tool-work
interface with good accuracy is essential. Several
experimental and analytical techniques have been
developed for the measurement of temperatures
generated in cutting processes. Due to the nature of
metal cutting, it is not possible to measure
temperature precisely in the cutting zone and thus it
is difficu lt to verity the theoretical results in a
precise manner. Because of nature of the metal
cutting, determination of internal temperatures on
the cutting tool are very difficult. For measuring of
this temperatures generated in the cutting zone,
several methods have been developed. Calorimetric
method,
thermocouple
method,
infrared
photographic technique, thermal paints and PVD
technique are some of them.
Tool-work thermocouple has always become a
popular tool to be used in temperature
measurements during metal cutting. This method is
very useful to indicate the effects of the cutting
speed, feed rate and cutting parameters on the
temperature. Thermocouples are conductive,
rugged and inexpensive and can operate over a
wide temperature range. In mach ining applications,
a thermo electric emf is generated between the tool
and the work piece. With these method, the entire
tool is used as a part of the thermocouple and the
work piece as the other part. The cutting zone
forms the hot junction while a cold part of the tool
and the work piece forms the cold junction. This
technique is easy to apply but only measures the
mean temperature over the entire contact area of
tool and workpiece. Based on these measurements
using the thermocouple method, Stephenson [9]
stated that the average emf is in tool work piece
interface.
W. Grzesik [10] investigated the influence of toolwork interface temperature when machin ing an
AISI 1045 and an AISI 304 with coated tools. A
standard k-type of thermocouple inserted in the
work piece was used to measure the interface
temperature. The friction on the flank face had a
big influence on the heat generated at about 200
m/ min cutting speed.
Trent and Wright [11]suggest that 99% of the work
done is converted into heat. This results in an
increase in the tool and work piece temperatures
Herbert, (quoted in (E M Trent, 1989[12]) used a
technique with tool-work thermocouple to analyze
chip-tool interface temperature variation under

@ 2013 http://www.ijitr.co m All rights Reserved.

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Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

different cutting conditions, such as the cutting


speed and depth of cut, as well as with different
cutting fluids. His results showed that temperatures
increased with increase in speed from 0.1m/s to
1m/s. Similarly, temperatures were high when
cutting dry, followed by cutting with an oil
lubricant, and finally with water as the cutting
flu id. Since water is the best conductor of heat
among the three choices, it gave the lowest
temperature, reinforcing waters ability as a good
coolant. Who achieved up to 30 to 40 % increase in
cutting speed when machining steel with high
speed steel tools using water as coolant. Despite its
excellent cooling ability water lacks lubricat ing
properties and causes serious corrosion problems
on the machine tool components as well as on the
work piece.
S. Ramesh et al.[13] has presented measurement
and analysis of surface roughness in turning
process of aerospace titanium alloy (gr5) under the
influence of machining parameters like cutting
speed, feed rate and depth of cut And they found
increase in value of surface roughness with
increase in feed, depth of cut and speed.
NeerajSaraswat et al.[14] studied the effects of
spindle speed, feed rate and depth of cut in turning
process on mild steel on surface roughness and as a
result of that the combination of the optimal levels
of the factors were obtained to get the lowest
surface roughness.
Astrand et al. [15] showed the coating layouts and
cutting tool edge geometry can significantly affect
heat distribution into the cutting tool. The paper
clearly shows the role and potential benefits of
applying different top coats on the rake and flank
faces with regards contact phenomenon, impact on
thermal shield ing and tool wear.

III. LITERATURE GAP AND OUR


APPROACH
Fro m the literature rev iew it is found that less
research work have been done regarding the tool
performance while coated with metal coating.
Similarly different approaches to coat the material
have not been tired. Physical vapor deposition and
chemical vapor deposition have been considered as
only method to coat the cutting tool.
Considering the literature gap observed our
approach is to coat the cutting tool with
Electroplating method which is much more
economical than PVD and CVD by metal (Nickel
and Zinc) and observe the performance of
mach ining process.
IV. EXPERIMENTATION
A. Selection of work piece
Aluminu m rod with diameter of 25 mm was
selected as work material.
Aluminu m is used in a huge variety of products
including cans, foils, kitchen utensils, window
frames, beer kegs and airplane parts. Th is is
because of its particular properties. It has low
density, is non-toxic, has a high thermal
conductivity, has excellent corrosion resistance and
can be easily cast, machined and formed. It is also
non-magnetic and non-sparking. It is the second
most malleable metal and the sixth most ductile.
Because of these uses and properties (TABLE I.)
the machining of aluminu m is one of the common
processes in manufacturing industries.
TABLE I.

PROPERTIES OF
ALUMINUM

Group

13

Grzesik et al. [16] found that method of elementary


balances
multilayer
coated
cutting
tools
performamce is better than uncoated tool.

Melting
point

660.323oC,
1220.581oF,
933.473 K

Period

Corduan et al. [17] found, PVD coated tool


performance is better than the CVD.

Boiling
point

2519oC, 4566oF,
2792 K

Block

2.70

Lin et al. [18]indicated that the feed had the


significance factor affect the surface roughness
followed by cutting speed.

Density
(g cm-3)

Atomic
number

13

Relative
atomic
mass

26.982

Key
isotopes

27

The machin ing of alu minum is most important


process on industry. Minimal lubricat ion
mach ining of alu minum alloys is identified and
optimization of cutting parameters by Kelly et al.
[19]

S tate at 20C

Solid

Electron
configuration

[Ne]
3s23p 1

Al

Nouari et al. [20]p rovedthe use of diamond as


coating material allowed to extend the tool life. The
combination of the optimized tool geometry and
the cutting conditions entails a high surface quality.

2320 5547

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Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

Figure 1.

Aluminum rod

B. Preparation of Workpiece
Aluminu m rod (Fig. 1) of 10 centimeter length with
good surface finish is required for further
mach ining process. The preparation of workpiece
involves the following steps:
1) Cutting into 10 cm pieces:The alu minu m
rod is cut into 10 cm pieces with the help of hand
saw. The aluminu m rod is held in vice as shown in
Fig. 2.

Figure 4.

Facing operation

3) Turning operation: The faced workpiece is


turned (Fig. 5) in lathe machine and appeoximately
1mm thickness is reduced. The main purpose of
turning operation is to make the outer surface of
workp iece smooth.

Figure 5.

Turning operation

C. Cutting Tool Selection


Figure 2.

Cutting Aluminum rod into pieces

The cut aluminum wo rkp ieces ready for facing


and turning operation areas shown in Fig. 3.

Figure 3.

Aluminum workpieces

2) Facing Operation: The cut piece of


alu minu m was held in lathe machine and facing
operation was performed to have smooth face as
shown in Fig. 4.

2320 5547

The tool selected for our experimental purpose is


high speed steel.
When tool steels contain a combination of more
than 7% molybdenum, tungsten and vanadium, and
more than 0.60% carbon, they are referred to as
high speed steels. This term is des criptive of their
ability to cut metals at 'high speeds'. Until the
1950's, T-1 with 18% tungsten was the preferred
mach ining steel but the development of controlled
atmosphere heat treating furnaces made it practical
and cost effective to substitute part or all o f the
tungsten with mo lybdenum. Additions of 5-10%
Mo effectively maximize the hardness and
toughness of high-speed steels and maintain these
properties at the high temperatures generated when
cutting metals. Molybdenum provides another
advantage: at high temperature, steels soften and
become embrittled if the primary carbides of iron
and chromiu m grow rapid ly in size. Molybdenum,
especially in comb ination with vanadium,
minimizes this by causing the carbides to reform as
tiny secondary carbides which are more stable at
high temperatures. The largest use of high-speed
steels is in the manufacture of various cutting tools:
drills, milling cutters, gear cutters, saw blades etc.

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Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

The useful cutting characteristics of high-speed


steel have been further extended by applying thin,
but extremely hard, t itaniu m carb ide coatings
which reduce friction and increase wear resistance,
thereby increasing cutting speed and tool life.
The exceptional high temperature wear properties
of molybdenum-containing high-speed steels are
ideal for new applications such as automobile valve
inserts and cam-rings.
Figure 8.

Experimental set up for turning

During the turning process pyrometer is used to


measure the temperature of tool-chip interface and
recorded value is noted.
The infrared thermo meter used to measure
temperature during experimentation is as shown in
Fig. 8.

Single point HSS cutting tool (left to


right: uncoated, Nickel coated, Zinc coated
and Cadmium dipped tool)

Figure 6.

D. Preparation Of Cutting Tool


High speed steel single point cutting tool is coated
with Nickel and Zinc separately by electrochemical
plating process.
The experimental setup for the coating process is as
shown in Fig. 7.

Figure 7.

Figure 9.

Infrared thermometer

Fig. 10 shows the workpieces after turning


process which are ready for surface roughness
measurement.

Electrochemical coating of cutting tools

E. Machining Operation And Measurement


After the preparation of workp iece and tool
material next step is to perform the turning
operation on the workpiece with the selected set of
values of feed, speed and depth of cut.
The experimental setup during the turning process
is as shown in Fig. 8.

Figure 10. Machined workpieces

After the turning process Taylor-Hobson Talysurfis


used to measure the roughness value of machined
workp iece.
F. Calculation of Material Removal Rate
MRR is defined as the total volume of material
removed fro m workpiece per unit time. MRR is a

2320 5547

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(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

criterion to analyze the productivity of a machining


process.

V.

RES ULTS AND DISCUSS ION

In this chapter the result of modeled proble m and


its experimentation is listed and analyzed to draw a
valid conclusion.

For turning operation, if


f is the feed value in mm/ rev,

G. Machining Parameters Used For


Experimentation

d is depth of cut in mm
and D is diameter of workpiece in mm

TABLE II. CUTTING PARAMETERS

Then volume of material removed fro m workpiece


per unit revolution is given by

Cutting speed
N (rpm )

If N is speed of workpiece in revolutions per min,


Then volume of material removed fro m workpiece
per minute is

Feed
(mm/rev )

Depth of cut
d( mm )

90

0.071

0.3

139

0.143

0.6

The Table II shows the numerical values of the


various machining parameters (cutting speed, feed
and the depth of cut) for experimentation.

Using this standard relation material removal rate


in turning operation can be calculated.
H. Experimental Result
In the following table the experimental result of turning aluminum workpiece with various tools in dry
environment is shown.
TABLE III.

S.N
.

EXPERIMENTAL RESULT FOR TURNING OF ALUMINUM WITH UNCOATED TOOL

Diameter(D)m
m

Feed
(f)

Speed(S)rp
m

Dept
h of
cut
(d)

mm/re
v

Temperature(T
)
C

Surface
roughnes
s

MRR(mm/min
)

Ra(m)

mm
1

24

0.071

90

0.3

35

0.853

144.54

24

0.071

90

0.6

37

0.734

289.08

24

0.071

139

0.3

35

0.981

223.23

24

0.071

139

0.6

39.5

1.341

446.46

24

0.143

90

0.3

37.4

1.921

291.11

24

0.143

90

0.6

37

2.12

582.23

24

0.143

139

0.3

38

2.321

449.60

24

0.143

139

0.6

37.2

2.403

899.21

TABLE IV.

S.N.

EXPERIMENTAL RESULT OF TURNING ALUMINUM WITH NICKEL COATED TOOL

Diameter(D)

Feed (f)

Speed(S)

mm

mm/ rev

rpm

Depth of
cut (d)

Temperature(T)
C

mm

Surface
roughness

MRR(mm/ min)

Ra(m)

24

0.071

90

0.3

39

2.28

144.54

24

0.071

90

0.6

40

2.579

289.08

24

0.071

139

0.3

42

3.481

223.23

24

0.071

139

0.6

43

2.873

446.46

24

0.143

90

0.3

40

2.314

291.11

24

0.143

90

0.6

41.5

2.98

582.23

2320 5547

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Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

24

0.143

139

0.3

43.5

1.78

449.60

24

0.143

139

0.6

46.7

1.813

899.21

TABLE V.

S.N.

EXPERIMENTAL RESULT OF TURNING ALUMINUM WITH ZINC COATED TOOL

Diameter(D)

Feed (f)

Speed(S)

mm

mm/rev

rpm

Depth
of cut
(d)

Temperature(T)
C

Surface
roughness

MRR(mm/min)

Ra(m)

mm
1

24

0.071

90

0.3

32

1.281

144.54

24

0.071

90

0.6

34.8

1.893

289.08

24

0.071

139

0.3

34.5

1.981

223.23

24

0.071

139

0.6

35.5

2.013

446.46

24

0.143

90

0.3

37

1.193

291.11

24

0.143

90

0.6

38

1.21

582.23

24

0.143

139

0.3

37.5

1.342

449.60

24

0.143

139

0.6

39

1.213

899.21

I. Validation Of Results
In order to verify the result obtained graph is
plotted between various input and output
parameters and compared with the standard result.
1) Variation of Temperature with input
parameters: Following graphs are plotted to
analyze the relationship between temperature at the
chip-tool interface with the input parameter speed,
feed and depth of cut. Moreover comparative plot
of temperature generated for uncoated tool, tool
coated with nickel and tool coated with zinc is
shown in follo wing graph.

Figure 12. Temperature vs Speed plot for uncoated

tool with feed rate=0.071

Figure 11. Temperature vs Speed plot for uncoated

tool for depth of cut=0.3mm


Figure 13. Temperature vs Speed plot for all three

types of tool with depth of cut=0.6mm& feed


rate =0.143mm/rev
2) Variation of Surface Roughness with
various input parameter: Following graphs are
plotted to analyze the relat ionship between surface
roughness of machined workpiece with the input
parameter speed, feed and depth of cut. Moreover
comparative p lot of surface roughness produced

2320 5547

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Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

with uncoated tool, tool coated with nickel and tool


coated with zinc is shown in fo llo wing graph.

J. Discussion
1) Temperature: During the turning operation
high amount of heat energy is produced by
shearing and rubbing action. Maximu m amount of
heat is carried by flowing chips and some amount
passes to workpiece and tool material. For the
given set of speed, feed and depth of cut the
temperature the maximu m temperature observed is
46.7 C. However if the values of speed, feed and
depth of cut are increased to high level the rise in
temperature will be high.
Fro m the plot of temperature with respect to speed,
it is clearly seen that with increase in speed the heat
generation process increases causing rise in
interface temperature.

Figure 14. Surface Roughness vs Speed plot for

machined surface with uncoated tool with


d=0.6mm

Similarly on increasing the feed value from


0.071mm/ rev to 0.0143mm/ rev at constant
temperature and depth of cut the rise in temperature
is observed.
In the similar fashion while increasing depth of cut
fro m 0.3mm to 0.6 mm keep ing the values of speed
and feed constant the temperature generated in
turning process is increased.
2) Surface Roughness: During the experiment
the surface roughness value is measured in terms of
roughness average (Ra) which is the arithmetic
mean deviat ion of surface profile fro m mean line.

Figure 15. Surface Roughness vs Speed plot for

machined surface with uncoated tool for feed


rate =0.143mm/rev

Fro m the plot of roughness value with speed it is


clearly seen that with increase in speed the surface
roughness increases. Similarly on increasing the
depth of cut from 0.3 mm to 0.6mm in most of the
cases surface roughness is increased. But no clear
relation was found between the feed value and
surface roughness value. May be this is owing to
the built-up edge formation on tool during the
mach ining process or due to use of same cutting
tool for a long time.
3) Uncoated Tool vs Coated Tool: Fro m the
comparative plot of temperature with speed for
uncoated tool, tool coated with zinc and tool coated
with nickel it is found that temperature generated
during machining with zinc coated tool is found
greater than during machining with uncoated tool
and nickel coated tool.
Fro m the heat generation point of view nickel can
be considered as a good material for tool coating
while zinc is not considered as good material for
coating fro m this project.

Figure 16. Surface roughness vs Speed plot for

machined surface with all three variety of


tools with depth of cut =0.3 mm& feed rate
ee=0.071mm/rev

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Similarly machining with nickel coated tool


produced good surface fin ish compared to uncoated
and zinc coated tool. Zinc coated surface produced
comparatively rough surface. So fro m surface
roughness point of view nickel can be considered
as a good material as cutting tool coating.

@ 2013 http://www.ijitr.co m All rights Reserved.

Page | 2241

Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

VI. CONCLUS ION


Following Conclusions can be drawn from the
result obtained from the machining of Alu minu m
workp iece with uncoated, Nickel coated and Zinc
coated tool individually under provided feed, speed
and depth of cut.

The experimentation showed that further


research can be proceeded for the coating
of tool with
metal coating by
electroplating method.

Measurement of tool-chip interface with


infrared thermo meter is a very fine
technology.

Temperature
of
chip-too
interface
increased with increasing feed, depth of
cut and speed.

Temperature released during machining of


alu minu m by zinc coated tool was high
compared to uncoated and nickel coated
tool.

Surface roughness value increased with


increase in speed and depth of cut.

No clear relationship was obtained


between surface roughness and feed of
tool.

Zinc coated tool produced rough surface


compared to uncoated tool but nickel
coated tool produced fine surface fin ish.

Fro m heat generation and surface finish


aspect nickel can be considered as a good
metal fo r cutting tool coating.
VII. SCOPE FOR FUTUR E WORK

With increasing demand of high quality product


with lesser price the manufacturing industry has be
competitive. Machining is the fundamental process
for any manufacturing process and companies are
always in seek of better technology the scope of
study in the performance of mach ining process is
high.
Some of the field of study for future work can be
listed as:

Research on electroplating coating of


cutting tool can be furthered because of its
cheapness and ease of technology.

Further research can be extended to study


the performance of single point cutting
tool with variety of metal coating.

Study on generation of heat during


mach ining can be studied with the use of
infrared thermo meter.

Since surface finish is a crucial factor for


any product manufactured the way to
increase surface fin ish may be a g reat field
of study.

Study can be continued on life of cutting


tool and its wear mechanis m.

Study on nickel coated tool can be


furthered because of its good behavior
towards heat generation and surface fin ish.
VIII.

ACKNOWLEDGEMENT

I would like to exp ress our heartfelt gratitude to our


project guide Dr. DampalaLingaraju, Assistant
Professor, Department of Mechanical Engineering,
UCEK, JNTUK, without whose valuable
suggestions, able guidance, continuous support and
encouragement, I could not have completed this
project work.
Our
deepest
gratitude
to
Dr.
B.
Balakrishna,Professor and HOD, fo r his everlasting
support and guidance during the course.
I am also immensely grateful to Pro f. Dr. K. Pad ma
Raju, Principal, UCEK, JNTUK and Prof. Dr.
P.SubbaRao, Vice-Principal, UCEK, JNTUK for
motivation and inspirational support during the
course of project work.
My sincere thanks to the teaching and non-teaching
staffs of University College of Eng ineering, JNTU
Kakinada for providing the necessary facilit ies to
complete the project.
I wish to express our gratitude to all those who
shared their pearls of wisdom with me during the
course of this project and also helped in its
successful completion at University College of
Engineering Kakinada.
Finally I would like to thank everyone who helped
in successfully comp leting thisproject.
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2320 5547

@ 2013 http://www.ijitr.co m All rights Reserved.

Page | 2242

Shreedhar Bhattarai* et al.


(I JI TR) I NTERNATI ONAL JOURN AL OF I NNOVATI VE TECHNOL OGY AND RESE ARCH
Volume N o.3 , I ss ue No.4, Jun e - July 2015, 2234 2243.

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