Experimental investigation of turning operation using carbide inserts

Experimental investigation of turning operation using carbide inserts

Department of Mechanical Engineering, Shree Tuljabhavani College of Engineering,Tuljapur -413 601 Department of Mechanical Engineering, Jawaharlal Nehru Engineering College, Aurangabad-431 006
vijaykagade@rediffmail.com

Abstract: This paper presents an investigation on the optimisation and the effect of cutting parameters on multiple performance characteristics (work piece surface roughness, spindle load) obtained by turning operations. A CNMG 09 03 08-PF carbide insert as tool and the HCHC steel as work piece material were used in experiments. The work piece material was machined under different settings of feed rate, depth of cut, cutting speed on a CNC lathe model-TL1 (HAAS). The results showed that cutting speed and feed rate were the dominant variables on multiple cutting performance characteristics. An optimum parameter combination was obtained by using experimental analysis.

II. EXPERIMENTAL DETAILS This experiment was conducted using the hardware listed in Table I on CNC lathe machine as shown in figure 1. A Cylindrical bar of HCHC steel (length 75 mm, diameter 70 mm) was used as work piece to carry out experiments on CNC lathe by a CNMG 09 03 08-PF carbide insert as cutting tool.
TABLE I HARDWARE LIST

Keywords: Surface roughness, spindle load, cutting parameters I. INTRODUCTION The materials having high-tensile strength and resistance to wear and impact, which are frequently used for drawing dies, blanking dies, forming dies, bushings, gauges, etc., are generally difficult to machine. HCHC-High carbon high chromium steel is one of these materials. For the machining of High carbon high chromium steels, the cutting tool materials must be harder than the work piece materials. These types of materials can be machined with carbide tools [1]. Among the cutting parameters affecting machining variables for steel, speed has maximum effect & depth of cut has minimum effect. Tool tip temperature increases with increase in cutting speed. At high speeds, surface finish is least affected. Surface finish deteriorates at high feed rates; hence to obtain good surface finish, feed rate may be kept low. At low speeds cutting force are high & tendency of work material to form a built up edge is also stronger. At lower speeds, surface roughness increases with increasing feed but at higher speeds surface roughness is less dependent on feed [2]. The Taguchi parameter design method is an efficient experimental method in which a response variable can be optimized, given various control and noise factors, and using fewer experimental runs than a factorial design [3].

Sr. no.

Item

Specifications Model-TL1 (HAAS) Spindle: Max. Speed- 2000 rpm; Torque- 136 Nm @ 375 rpm; Max. Power Rating 5.59 KW; Spindle Nose- A2-5; Spindle Bore Dia.-59 mm Travels & Feed rates: X-axis209 mm; Z-axis- 762 mm; Xaxis Max. Thrust- 133.772 KN; Z-axis Max. Thrust- 886 KN; Rapids on X-axis- 1.9 m/min; Rapids on Z axis- 308 m/min General: Weight- 1860 Kg; Power requirement- 9 KVA ;1phase : 240 V @ 40A; 3-phase : 208 V Hommel werke Surface TesterMeasures Ra in m; CNMG 09 03 08-PF

CNC lathe

2 3

Surface roughness measurement device Cutting tool inserts

III. RESULTS & DISCUSSIONS Work piece material HCHC-High Carbon High Chromium contains C-1.5% or more than 2%, Cr12%, Mo-1% & some traits of W & V. It can maintain sufficient hardness up to 500 C due to presence of alloy carbides [4]. It has got Low thermal conductivity. It is difficult to machine. It has got good wear resistance [5]. It is observed that while machining HCHC work piece material continuous chips are formed. From Table II which shows 87

International Journal of Applied Research in Mechanical Engineering, Volume-1, Issue-1, 2011

Experimental investigation of turning operation using carbide inserts

experimental data related to surface roughness characteristics three graphs are plotted using MS Word 2007 software application.

Fig. 1 CNC Lathe

TABLE II EXPERIMENTAL DATA RELATED TO SURFACE ROUGHNESS CHARACTERISTICS

Graph No. I

Sr. No. 1 2 3 4 5 6 7 8 9

Speed in RPM 1700 1800 1900 1900 1900 1900 1900 1900 1900

Feed in mm/rev 0.1 0.1 0.1 0.1 0.2 0.3 0.1 0.1 0.1

II

III

Depth of cut in mm 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.3

Surface roughness in microns (m) Rmax Rz Ra 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.9 0.2 0.0 4.62 11.1 2.1 6.8 6.4 1.5 4.80 3.98 0.82 4.82 4.42 0.84 5.52 4.74 0.86

Spindle Load in KW 0.5 0.6 0.6 0.7 0.9 1.0 0.6 0.8 1.1

It is observed from the Graph I of Ra Vs Speed when Feed=0.1 mm/rev & Depth of Cut=0.1 mm that when feed & depth of cut are kept constant & only speed is increased continuously after certain maximum value of 1700 rpm then we can obtain almost negligible value of surface roughness.

1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 1700 1800 1900

Ra in m

Speed in RPM
Graph: -I Ra Vs Speed Graph when Feed=0.1 mm/rev & Depth of Cut=0.1 mm

From graph II of Ra Vs Feed when Speed=1900 RPM & Depth of Cut=0.1 mm it is observed that when speed & depth of cut are kept constant & only feed is feed rate i.e. 0.2 mm/rev & after this as feed increases then surface roughness decreases.

increased continuously then surface roughness also increases continuously up to certain higher value of

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Experimental investigation of tu urning operation using carbide inse erts

2.5 5 2

IV CONC CLUSIONS Among the cutting par t rameters affec cting the surface roughnes for HCHC steel, speed has maximu ss um effect & depth of cut has minimum effect. At hig m gh speeds, surface finish is least affected At low speeds d. surface roughness incre r eases with increasing feed b but at higher speeds surfac roughness is less depende r ce s ent on feed Hence fro d. om the abov experiment ve tal investiga ation it is fou und that optim mum values of cutting parameters for machining o HCHC work p r of piece ma aterial using a CNMG 09 03 08-PF carbid 3 de insert as cutting tool ar speed= 170 rpm or mor re, 00 re, feed= 0.1 mm/rev, & de 1 epth of cut= 0.05 to 0.1 mm. ACKNOW WLEDGMENT I offer my most sin ncere humble thanks to m my d f.R.R.Deshmuk kh, Mechanic cal esteemed guide Prof Engineer ring Departm ment, Jawa aharlal Neh hru Engineer ring College, Aurangabad. Not only f for giving ble guidance, unflaggin ng his valuab encourag gement and in nspiration, bu also for h ut his never-end ding willingne to tender generous. I a ess am also than nkful to Mr Aw wasekar Gopal Sir (CAD/CAM M Manager), Mr Rakewar Sir & all othe staff membe r er ers at Indo G German Tool R Room, Auranga abad for makin ng available all the fa e acilities for the successf ful completio of this work on k.

Rainm

1.5 5 1 0.5 5 0 0.00 0.50 1.0 1.50 2.00 2.50 3.00 3.5 00 50 Fe eedX.1inmm m/rev

Graph: -I Ra Vs Feed G II Graph when Speed d=1900 RPM & Depth of Cut=0.1 mm f

From grap III of Ra Vs Depth of Cut when ph R n Speed=190 RPM & Fee 00 ed=0.1 mm/rev it is observed v d that when speed & feed are kept constant & only d y cut ed y e depth of c is increase continuously then surface roughness also increases continuously. Also as speed d increases continuously the spindle load is also o increases continuously. Maximum value of spindle c e load occurs when value o depth of cut is high. of 0.8 87 0.8 86

Rainm

0.8 85 0.8 84 0.8 83 0.8 82 0.8 81 0 1 2 3 4

NCES REFEREN 1. Op ptimisation for ho turning opera ot ations with multip ple performance cha p aracteristics- N. Tosun E. L. Ozle erInt J Adv Manuf Technol (2004) 23: 777782 DOI uf ) 10.1007/s00170-0 003-1672-4 Ma achining behaviou of AISI 1018 st during turnin ur teel ng - Suresh Dhima an,Rakesh Sehga al,S K Sharma & Vishal S Sharma a-Journal of Scie entific & industr rial Research; vol.67, May 2008, pp.355-360 Op ptimizing surface finish in a turn ning operationusi ing the Taguchi par rameter design m method- E. Dan niel Kirby . Zhe Zhan .Joseph C. Che . Jacob Chen- I ng en Int J Adv Manuf T Technol (2006) 30: 10211029 DOI 10.1007/s00170-0 005-0156-0 Ma aterial Science & Metallurgy by V.D.Kodgire, pg438 V 8 Ma aterial Science & Metallurgy by O.P.Khanna, pg5-3 O 32

thOfCutX0.1inmm Dept
2. Graph: - II II Ra Vs Depth of Cut Graph wh Speed=1900 h hen RPM & Fe eed=0.1 mm/rev 3.

4. 5.

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