Experimental Investigation on Effect of High Pressure Coolant with Various Cutting Speed and Feed on Surface Roughness in Cylindrical Turning of AISI 1060 Steel Using Carbide Insert

Arunachalam²

2020

Eng. Res. Express

In the present study, the effect of cutting speed, feed rate, and tool nose radius on the forces, cutting power and tool life has been investigated in machining ductile iron. Face milling inserts with 0.8 mm and 2 mm corner radii were tested at three different cutting speeds and feed rates. The experiments were conducted using a full factorial design method and the Analysis of Variance (ANOVA) technique was used to determine the significance of each variable that is responsible for the variation in forces and machining power. AdvantEdge finite element analysis software was used to study the stress zones and temperature distribution on the cutting edge. The study shows that when the feed rate is increased, there is a linear increase in the radial (Fx) and cutting (Fy) forces. The contribution of feed rate on Fx and Fy forces was around 80% and 87%, respectively. However, with a significance of around 17%, the effect of the tool nose radius was pronounced more in the axial direction (Fz force). The finite element analysis showed higher temperature and stress regions in the nose radius zone of the tool with 2 mm corner radius. The lesser contact area between the tool and workpiece of the insert with 0.8 mm nose radius resulted in lower axial force, lower friction, and increased tool life by around 57%.

Section: Forcesmentioning

confidence: 54%

Section: Introductionmentioning

confidence: 99%

Analyzing the effect of cutting parameters and tool nose radius on forces, machining power and tool life in face milling of ductile iron and validation using finite element analysis

Arunachalam²

2020

Eng. Res. Express

“…Generally, the surface roughness of a machining operation can be controlled by optimizing the cutting parameters [23] or by changing the geometrical features of the tool like corner radius and wiper facet [24]. However, the work-material-dependent properties like composition, mechanical, and metallurgical properties also play a role in determining the surface roughness.…”

Section: Surface Roughnessmentioning

confidence: 99%

Machinability analysis in high speed turning of Ti–6Al–4V alloy and investigation of wear mechanism in AlTiN PVD coated tungsten carbide tool

Murugesan²

2021

Eng. Res. Express

Titanium alloys are one of the most critical and prominently used materials in automotive, aerospace, and biomedical application due to their superior strength to weight ratio. The very property that makes it a suitable material for such applications also makes it challenging to machine. In this study, an attempt has been made to understand the machinability of Ti–6Al–4V titanium alloy at high cutting speeds in turning. A full factorial method and Analysis of Variance (ANOVA) technique were used to conduct 18 different experimental runs and determine the significance of variables that are responsible for the variation in average surface roughness (Ra) and forces. The results show that feed rate is the single most significant factor for Ra, whereas the contribution of feed and depth of cut are more for the forces, followed by cutting speed. Tool life tests were conducted with AlTiN PVD coated tools at three different cutting speeds, and SEM analysis to evaluate the wear mechanism revealed that abrasive wear, notching, and diffusion were predominant which accelerated the wear rate. Although machining studies on Ti6Al4V at low cutting speeds are well established, the novelty of the study is to perform a comprehensive analysis to evaluate the machinability and study wear mechanism using AlTiN coated tungsten carbide tool at high cutting speeds.

“…Among these variables, the micro-geometry of the tool plays a major role in determining the stress distribution and tool wear [1]. In terms of cutting parameters, increasing the cutting speed improves the surface finish and decreases the forces, whereas increasing the feed rate reduces surface quality and increases the force [2,3].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Effect of Different Micro-Geometries on Cutting Edge and Wiper Edge on Surface Roughness and Forces in Face Milling

Nagarajan²

2021

Lubricants

The significance of the micro-geometries on the cutting edge is known from numerous studies conducted in the past. However, the effect of micro-geometry on the wiper facet (also called the wiper edge) is not known. Hence, this paper investigates the effect of different micro-geometries with a focus on geometry variation on the wiper edge of a milling insert on surface roughness and forces in face milling of SAE1070 high-carbon steel. Milling inserts with sharp, rounded, chamfered edges and their combinations were manufactured on the cutting edge and wiper edge for the study. Critical surface quality parameters such as the average surface roughness (Ra), mean depth of surface roughness (Rz), and force components such as radial force (Fx), cutting force (Fy), and axial force (Fz) were evaluated. Metal cutting tests were performed at three different cutting speeds and three different feed rates to study the influence of cutting parameters and the effect of edge geometries on surface roughness. The results were correlated with the force values to understand the machining dynamics. Finite element analysis was performed to evaluate the high and low-stress zones on the insert, workpiece, and chip to understand the metal cutting mechanism of different micro-geometries. The novel finding from the study is that having identical micro-geometries on the cutting and wiper edge is the preferred combination, whereas dissimilar micro-geometries result in reduced surface quality, increased forces, and high stress on the workpiece and chip.