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I1
ABSTRACT
This study presents tool wear characterization of carbide cutting tool inserts coated
with titanium nitride (TiN) in a single point turning operation of AISI D2 steel. A set
of experiments of 20 settings of cutting speed, depth of cut and feed rate were
performed on a CNC lathe without coolant. Surface roughness was measured by
Mitutoyo profilometer (SJ-301) and flank wear was measured by Axioskop 40 and
the data was compiled into Design Expert 7 software for analysis. From the result,
cutting speed was found to be the main factor to have significant effect on surface
roughness as well as flank wear. Depth of cut was also found to have interaction with
cutting speed to produce significant effect to surface roughness. No interaction
between the factors was found to give significant effect to flank wear. At the end of
this study, optimization was made by suggesting the most suitable sets of parameter
settings to produce minimum surface roughness and to produce minimum flank wear.
Suggestion on parameter settings to obtain both minimum surface roughness and
flank wear was also made.
ABSTRAK
CHAPTER 1
INTRODUCTION
1.
Background
There are other various reasons to eliminate the usage of coolant. Lubrication in the
machine shops contributes about 15 percent of the production cost (Schneider 2001).
In other words, if use of lubrication is eliminated, the production cost can be reduced
up to 15 percent. Lubrication also contributes to pollution. The waste cutting fluid
cannot be disposed off without treatment. This will even increase the cost of
production. Other than water pollution, air pollution also takes place when coolant is
used. During machining, air-borne mist is produced. There is a certain limit fixed by
Occupational Safety and Health Administration (OSHA) to the mist produced by the
coolant into the air. In conclusion, eliminating coolant by implementing dry cutting
brings many benefits to the industry.
1.2
Problem Statement
Tool wear is inherent in machining. There are many steps and measures taken to
reduce the effect of tool wear on cutting tools. One of the steps is applying surface
treatment on the base cutting tool material. A popular method is applying coating
onto the base cutting tool material by the use of physical vapor deposition (PVD)
method. By studying the behaviour of the tool wear with respect to machining
parameters, tool life can be optimized by choosing the right machining parameters.
The optimum tool is not necessarily the least expensive or the most expensive, and it
is not always the same tool that was used for the job last time. The best tool is the
one that has been carefully chosen to get the job done quickly, efficiently and
economically (Schneider 2001). Because of this, it is necessary to characterize
specific cutting tool, coating material and work piece combination to understand the
interaction between machining parameters and tool wear performance. In this study
the combination of TiN coated carbide tool and D2 work piece was evaluated using
single point turning under dry machining condition.
1.3
Objective
1.4
Scope
This study focuses on tool wear characterization of carbide cutting tool inserts coated
with TiN. The types of tool wear to be analyzed are crater wear and flank wear. The
machining process done is a single point turning operation with no coolant involved
(dry cutting). The machining parameters evaluated are cutting speed, feed rate and
depth of cut. The work specimen or material machined is AISI D2 steel. The surface
finish of the machined work is also being taken into account. All of the
experimentation will be done using design of experiment (DOE) approach.
CHAPTER 2
LITERATURE REVIEW
2.1
Overview
In this chapter, related published works by other researchers like journals are
reviewed. These works or studies are the ones involving machining and cutting tools.
Other related information mainly obtained from books and articles are also included.
This review covers turning operation, machining parameters and cutting conditions,
cutting tool insert (carbide coated with titanium nitride), tool wear in the turning
operation, work piece material (AISI D2 steel) and the selected design of experiment
method.
2.2
Turning Operation
Turning operation means that when the machining process is running, the work
material moves in a rotational direction. The machine tool used for this operation is
the lathe machine. This is shown in Figure 2.1. The cutting tool is the section that
will be moving. In other words, the cutting tool will feed onto the rotating work
material. The material removal process is shown in Figure 2.2. The material is
removed layer by layer depends on the depth of cut until the desired dimension is
reached.
Cutting Tool
2.3
From metalworking point of view, a cutting tool can generally be stated as a tool
used to remove material from a work piece (work material) usually by the use of
abrasive cutting and shear deformation. Schneider (2001) stated that for a cutting tool
to be able to do its job efficiently, the cutting tool needs to have certain
characteristics of which three of them are listed below.
a)
b)
2.3.1
The term insert is applied when a cutting tool is screwed or clamped onto a tool
holder to be fixed on a machine tool; where in this particular study, the machine tool
would be a CNC lathe machine. Most of high-performance cutting tools use the
insert method. Inserts are normally made symmetrically so that when the first cutting
edge is dull they can be rotated, presenting a fresh cutting edge. This will effectively
increase the life of the tool insert. Figure 2.3 shows some different shapes of cutting
tool insert.
2.3.2
Carbide tools are one of the most common cutting tool material used in the industry.
~f
to carbon steels and high speed steels, carbide tools can machine much
faster at higher speed. Carbide tools can also work at higher working temperature.
Figure 2.4 shows a set of TiN-coated carbide cutting tool inserts and Figure 2.5 show
a cutting too1 insert fixed to a holder and lathe machine.
Figure 2.5: Cutting tool insert fixed to a holder and lathe machine
Coating of cutting tool has to have some characteristics of which some are shown
below.
Hardness : A high surface hardness from your coating is one of the best
ways to increase tool life. Generally speaking, the harder the material or
surface, the longer the tool will last.
b)
c)
d)
In general, the performance of TiN coatings is superior than others in their class and
the current state of the art of TiN may be further enhanced in the future (Smith et al.
1996).
2.4
Tool Wear
Tool wear can generally be described as the gradual failure of cutting tools due to
regular operation. There are many type of tool wear that includes edge wear, nose
wear plastic deformation, mechanical breakage, crater wear and flank wear. There
are many reasons to how these wear happen. For instance, mechanical breakage can
be caused by excessive force that causes immediate failure or thermal forces that
could also cause the wear. The machining parameter settings of the operation are
known to be one of the most common factors that cause tool wear. From a study on
rnrface finish and flank wear using multiple regression models and neural network
models done using turning as the machining operation, it is suggested that the best
tool life was obtained in lowest feed rate and lowest cutting speed combination (Ozel
et al. 2007).
crater \\.ear
cermets during dry machining said that with the increase in speed and feed rate,
cutting becomes steady with a consequent reduction in the cutting force.
2.4.2
Flank Wear
Flank wear occurs on the relief face of the tool and is generally caused by the
rubbing of the tool along the machined surface (Figure 2.7) that causes adhesive
and/or abrasive wear or from very high temperature machining that affects the tool
material properties as well the work piece surface (Kalpakjian & Schrnid 2001).
KB = crater width
TO
measure the tool wear, the major cutting edges is divide into four zones.
- Zone C is the curved part of the cutting edge at the tool corner.
- Zone B is the remaining straight part of the cutting edge between zone C
and zone A.
- Zone A is the quarter of the worn cutting edge length b farthest away from
the tool corner.
- Zone N extends beyond the area of mutual contact between the tool and
workpiece for approximately lmm to 2mm along the major cutting edge. The
wear is of notch wear.
The width of the flank wear land VBB shall be measured within zone B in the tool
cutting edge plane P, perpendicular to the major cutting edge and from the position
of the original major cutting edge. The crater depth KT shall be measured as the
maximum distance between the crater bottom and the original face in zone B.
2.5
Work Material
From the characteristics of the steel listed above, it can be suggested that AISI D2
steel is not one of the easy to machine work material. This is good for the study
because this study focuses on tool wear that resulted from turning operation. Using
N s I D2 steel, tool wear can be generated on the inserts with minimal machining
time. Figure 2.9 shows AISI D2 steel work material.
There are other standards for the code of the AISI D2 steel used around the world.
The 'D2' code is based on AISI standard. Even with different code names, they are
still the same steel. For example, in United Kingdom, they use the code B.S. B D ~
while in Germany it is DIN 1.2379.
AISI D2 steel is one of the most widely used steel in the industry. AISI D2 steel is
recommended for tools requiring very high wear resistance, combined with moderate
toughness (shock-resistance). It can also be supplied in various finishes, including
the hot-rolled, pre-machined and fine machined condition. Some of the many
applications of ATSI D2 still can be seen in the list below.
a)
Coining Dies
b)
c)
Thread-Rolling Dies
d)
Crushing Hammers
e)
f)
Knurling Tools
g)
Dies for molding of ceramics, bricks, tiles, grinding wheels and abrasive
plastic.
Surface Roughness
2.6
b)
residual stresses
c)
metallurgical transformation
d)
A study done using response surface methodology (RSM) on a turning process stated
that the feed rate was found out to be the dominant factor on the surface roughness,
but it decreased with decreasing cutting speed, feed rate and depth of cut for these
tools. (Sahin & Motorcu 2007).
The datum line is placed at the center of the graph so that the sum of the area above
and below the line is equal Figure 2.10.
Digitized data
Surface profile
Surface roughness measuring instruments used are called surface profilometers. The
instrument will measure and recode the surface roughness. The most co-only
used
are the ones using diamond as the stylus. The stylus will travel in a straight line on
contact with the surface to be measured Figure 2.11.
2.7
Design of Experiment
RSM, the best value of the values of the response cannot be obtained. This is when
RSM comes into play. An important aspect of RSM is the Central Composite Design
(CCD). CCD is very useful for building a second order or quadratic model for the
response variable without needing to use a complete three-level factorial experiment
(NIST 2006).
Design Expert software is used to define experimental matrix. The experiment will
be done using predetermined settings and improvement and optimization will be
done afterwards. For every input parameter for the experiment, the minimum and
maximum value is determined on the software and the software will produce a series
of matrix for the experiment. The experiment will be done based on this matrix.
Linear regression is used in RSM to predict experimental input and output
relationship. Three major analyses to be carried out are the main factor, interaction
and ANOVA.
According to NISTISEMATECH, the advantages of RSM are as follows.
a)
b)
c)
d)
e)
The use of RSM allows for bringing more knowledge earlier in the design
process
f)
g)
Instantaneous evaluations
The use of RSM and DOE along with the methods for running the whole study is
discussed on the next chapter.
CHAPTER 3
METHODOLOGY
2.1
Overview
This chapter covers the methods for running and completing the whole project. Every
detail on the project and how to run the experiment is included also. From the type of
material and obtaining the result to analyzing and finalizing the report. Every step to
be gone through is also featured in this chapter. The flow and sequence of the whole
project can be seen in Figure 3.1.
We Sele
Litcsrature F
Machining
--- .- - .--
--
.-
-- -
Measure
IQCIZ rouahn
flank.
Input Dal
3ta Anal)rsis
-it Sumnnary
lode1 sellection
I
I Significant
Lack of Fit
.... .
-
1-1
-
4
a
2,"
3.2
Literature Review
Literature review requires reviewing of other previous published works that could be
related to the study or that have useful information to be used in the study. It includes
gathering of information from books and resources from the internet. In literature
review, the information and theory regarding the experiment and the machining
process which is single point turning is defined. The inputs for the experiment is the
three machining parameter that are cutting speed, feed rate and depth of cut. As for
the output responses from the machining process, there are two responses to be
considered that are tool wear and surface roughness. To be able to obtain the result
from experiment, it is essential to know how to measure them. There are certain
equipments to be used for measuring them that will be discussed later on in this
chapter. Only then the analysis from the result can be made using Response Surface
Methodology (RSM).
3.3
Experiment
Depth of cut
Feed rate
There are two responses that are collected from the experiment that are as follows.
Response 1
Response 2
Flank wear pm
Surface Roughness pm
Specifications
cutting edge length, I = 12.7mm
0 d = 12.7mm
thickness, s = 3.1 8mm
AlSl 0 2 steel, dia. = 100mm
length = 250mm
Com osition %
Mo
0.1
3.3.3 Equipments
Single point turning was selected as the machining operation and the machining
process was done using HAAS CNC lathe machine. Figure 3.2 shows the machining
process running. The model number for the machine is SL 20T. All experiment was
done using this machine. The machining process was done without the use of coolant
(dry machining). For the response from the experiment, there were two measuring
equipments used. The tool wear was measured using Toolmaker's Microscope,
model number Axioskop 40 and manufactured by Zeiss Carl. For surface roughness,