INVESTIGATION ON TURNING OF STAINLESS STEEL(GRADE J4) USING CHILLED AIR MACHINING TECHNIQUE

TEAM MEMBER Abhishek Kumar Ajit Kumar Ashish Kumar Deep narayan gautam Dinesh Kumar

PROJECT GUIDE Mr. A.Tamilarasan ,M.Tech. Asst. Prof. / Mech. Engg.

OBJECTIVE
To get optimum surface roughness value for the turning of

Jindal stainless steel [Grade J4] in term of cutting speed, feed rate and depth of cut assisted by chilled air cooling technique. Machining work carried out using CVD Multi coated carbide

tool under different cutting conditions.

To indentify tool wear through SEM analysis.

WORK MATERIAL
Work material used was stainless steel [Grade J4], family of

stainless steel in the 200-series and these grades are austenitic,

they are not magnetic. Good formability and weldablity. Excellent toughness (impact resistance) even to very low cryogenic temperatures ferrite grades have poor low temperature toughness.

 The chemical composition of stainless steel Cr-Mn is C 0.115% , Cr 14.69%, Mn 7.97% ,Ni 0.263% etc. The acidic nature of the sugar cane juice and toxicity associated

with gaseous product encountered in the manufacture of sugar,

pose a serious challenge to sugar industry. Chrome-Manganese austenitic stainless steels are suggested to keep the performance-cost ratio reasonably economic.

TOOL MATERIAL
We used TNMG multilayer coated insert. Inserts were coated with

TiN/Al2O3/TiC.
TiN offers low friction and improved resistance to built-up edge. A TiC coating has high hardness and excellent wear resistance. Al2O3 provides a heat barrier with low thermal conductivity which protect the substrates. Coating may be a single-layer or multi-layer and typically 5-20 microns in thickness.

TOOL INSERT & TOOL HOLDER

Tool holder MTJNR 2525 M16

RECENT COOLING TECHNIQUE LUBRICATION

High pressure lubrication (HPL)

Minimum quantity lubricant (MQL)

Steam cooling

Solid coolant
Chilled Air Assisted machining technique

COLD AIR GUN

HOW VORTEX TUBE WORKS

Compressed air are injected tangentially into the vortex through the nozzle.

tube

Accelerated to a high rate of rotation of about 1,000,000 rpm.

Air stream moves towards the hot end where some air escapes through the control valve. Remaining air is forced backed through the centre of the vortex tube losing their kinetic energy.

EXPERIMENTAL METHODOLOGY
An experimental of prior experimental studies, a methodology was developed to study the surface roughness of the machined part in turning. CUTTING CONDITIONS Cutting tests were carried out on the medium duty lathe machine

under chilled air assisted condition.

The tools were tested under a various spindle speed of 208, 310, 320 RPM. The feed rate used was varied from 0.07mm/rev to 0.2mm/rev. The depth of cut varies from 0.1mm to 0.5mm.

Sl. no.

Cutting speed (Vs) m/min.

Feed rate (f) mm/rev.

Depth of cut (mm)

Ra (micron)

1. 2. 3.

20.91 20.91 20.91

0.07 0.09 0.2

0.1 0.3 0.5

1.00 1.61 3.46

4.
5. 6. 7. 8.

31.16
31.16 31.16 32.16 32.16

0.07
0.09 0.2 0.07 0.09

0.3
0.5 0.1 0.5 0.1

1.23
1.91 2.13 1.37 0.94

9.

32.16

0.2

0.3

2.14

EXP. NO: 01

EXP.NO: 02

EXP.NO: 03

EXP. NO: 04

EXP.NO: 05

EXP.NO: 06

EXP. NO: 07

EXP.NO: 08

EXP.NO: 09

RESULT AND DISCUSSION

The experimental results were analysed using analysis of variance(ANOVA) for identifying the significant factors affecting the performance measures.
Residual for Ra

Source DF Seq SS Adj SS Adj MS F P _______________________________________________________________________________ Vc 2 0.43742 0.43742 0.21871 6.45 0.134 F 2 3.16549 3.16549 1.58274 46.67 0.021 DOC 2 1.22829 1.22829 0.61414 18.11 0.052 Error 2 0.06782 0.06782 0.03391 _______________________________________________________________________________ Total 8 4.89902 _______________________________________________________________________________ S = 0.184150 R-Sq = 98.62% R-Sq(adj) = 94.46%

The total variation is the sum of variation due to various controlled factors , their interactions and variation due to experimental error.

Effect of feed is important as the statistical significant values less

than (0.05)value at 98.62% confidence level. R- sq represent the regression confidence larger values of R-sq is always desirable. The R sq values are 98.62% which shows the high correlation that exits between the experimental values and predicated values.

Main Effects Plot for Means

Data Means
VC 2.5 2.0
Mean of Means

1.5 1.0 20.91 2.5 2.0 1.5 1.0 0.1 0.3 0.5 31.16 DOC 32.16 0.07 0.09 0.20

Fig 2 main effect plot for means

RESPONSE TABLE FOR SIGNAL TO NOISE RATIOS SMALLER IS BETTER

LEVEL1 1 2 3 DELTA

Vc -4.973 -4.662 -2.935 2.038

F -1.511 -3.073 -7.986 6.475

DOC -2.010 -4.181 -6.379 4.369

RANK

RESPONSE TABLE FOR MEANS

LEVEL1 1 2 3 DELTA RANK Vc 2.023 1.757 1.483 0.540 3 F 1.200 1.487 2.577 1.377 1 DOC 1.357 1.660 2.247 0.890 2

 The response table show the average of response characteristic at each level and factor. Rank is based on delta statistics ,compare the relative magnitude of effects. The delta statistics is the highest minus the lowest average of

each factor.
From means the response ,cutting speed 32.16m/min, 0.07mm/rev feed and 0.1mm depth of cut good for surface finish.

EFFECT OF CUTTING SPEED DURING MACHINING

Cutting Speed Vs Surface Roughness
1.01 1 0.99 0.98 0.97 Ra (m) 0.96 0.95 0.94 0.93 0 5 10 15 20 25 30 35 cutting speed in RPM

Surface roughness inm

EFFECT OF FEED RATE DURING MACHINING

Feed Rate Vs Surface Roughness
1.4 1.2 Surface Roughness in m 1 0.8 0.6 0.4 0.2 0 0 0.05 0.1 0.15 0.2 0.25 Feed Rate in (mm/rev.) Ra (m)

SEM ANALYSIS
Dominant wear was observed at early stage of cutting . Discrete micro-chipping of the cutting edge is observed at low

cutting speed .
Flank wear occurs on the relief face of the cutting tool.

The flank wear is characterized by the abrasive grooves and

ridges on the flank face. Crater wear occur on the rake face of the tool.

Flank Wear

Crater Wear

CONCLUSION
Feed rate provide the primary contribution on surface roughness. Depth of cut is less significant.

Application of chilled cold air give the best result of surface finish.
At 32.16m/min spindle speed, 0.07 mm/rev feed rate and 0.1mm depth of cut gives the best result of surface finish.