Influence of cutting environments on surface integrity and power consumption of austenitic stainless steel

Abstract

Surface roughness is a result of the cutting parameters such as: cutting speed, feed per tooth and the axial depth of cut, also the tool’s geometry, tool’s wear vibrations, etc. Moreover, the surface finish influences mechanical properties such as fatigue behaviour, wear, corrosion, lubrication and electrical conductivity and the combination of cutting parameters influence the power consumption during the machining process affecting the environment. The research reported herein is focused mainly on searching for an optimum combination of cutting parameters to obtain a low value of surface roughness and minimize energy consumption when milling an austenitic stainless steel in different cutting environments. The experiments were conducted on a Siemens 840D Bridgeport Vertical Machining Centre 610XP2. The selection of this workpiece material was based on it’s widely applications in cutlery, surgical instruments, industrial equipment and in the automotive and aerospace industry due to its high corrosion resistance and high strength characteristics. The results show that the dry cutting environment is the best option in terms of power consumption and surface roughness values to conduct the milling of an austenitic stainless steel under the selected cutting parameters

Effects of cutting parameters on surface roughness and hardness in milling of AISI 304 steel

“…The result of cutting speed agrees with what is generally accepted, and with studies by Ozcelik et al [4], Hamdan et al [5], Thangarasu et al [6], Muñoz-Escalona et al [9], Kumar and Venkateswara [19].…”

“…As for feed rate, it is usually assumed that surface roughness increases with the increase of feed rate, but not in linear proportion [18]. In the present study, a lower value of surface roughness was obtained at a lower feed rate, coinciding with the investigations of Hamdan et al [5], Nurul et al [7], Muñoz-Escalona et al [9].…”

“…Muñoz-Escalona et al [9] showed that dry cutting environment was the best option in terms of power consumption, surface roughness and materials microhardness values in milling of AISI 303 steel. The authors emphasized that high cutting speed with less feed rate improved these results.…”

“…Based on this review, studies focused on searching for an optimum combination of cutting parameters to obtain a better value of surface roughness such as: high speed machining by Thangarasu et al [6]; articles on medium speed machining by Nurul et al [7], Maurotto et al [8], Muñoz-Escalona et al [9], as well as Kumbhar et al [14]. However, there is not much research on low cutting speed, and the effect of feed rate and cutting speed on workpiece hardness has not been considered; therefore, these are the aims of this work.…”

Calculation and Estimation of Surface Roughness and Energy Consumption in Milling of 6061 Alloy

“…e effects of tool features on power consumption during the processes of drilling and turning were examined by Neugebauer et al [12]. In addition, Muñoz-Escalona et al measured the energy consumption and surface roughness in the end milling of austenitic stainless steel under cryogenic, fluid coolant and dry cutting conditions [13]. Nas and Ozturk applied face milling to a spheroidal graphite cast iron workpiece, measured the increase in the consumed power index (PI) with an ammeter device, and optimized the machining process with two different cutting tools [14].…”