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Tool Wear Analysis-Full Paper (1) (1) (3580)
Tool Wear Analysis-Full Paper (1) (1) (3580)
Keywords: Turning, Cutting Fluid, Tool Wear, Surface Roughness, Taguchi Method, ANOVA
Abstract. In metal cutting, increasing cutting spped and feed achieve higher productivity, but it
will affect dimensional accuracy and surface integrity of the work surface, wear resistance and life
of tool. Cutting fluids when appropriately chosen and applied will minimize these problems. This
work deals with the optimization of process parameters in turning of EN24 and SS316L Steels with
different cutting fluids with different cutting inserts under different machining conditions using
Taguchi’s Robust Design Methodology. The control factors selected are machining environment,
cutting speed, feed, depth of cut, work piece material and type of tool. Investigations are carried out
on conventional lathe using the prefixed cutting conditions. Tool Wear and Surface Roughness are
measured and anlysed using ANOVA and appropriate conclusions are derived.
Introduction
The cutting tool plays an important role in achieving economical metal removal rate and quality of
the surface produced. The major difficulty faced during machining is the heat generated in the
primary and secondary cutting zones. As a consequence, the cutting temperatures in the tool, work-
piece interface rise significantly during machining. Emulsion-based cooling fluids with nano
powders with minimum quantity lubrication is used in metal cutting for a variety of reasons such as
improving surface finish, tool life, flushing away chips, and reducing work piece thermal
deformation [1]. Application of solid lubricant in metal cutting is a possible substitute to cutting
fluid, if it can be applied properly. Solid lubricants reduce friction between two surfaces sliding
against each other without the need for a liquid cutting fluid [2]. For machining harder alloys,
synthetic oil applied on the rake surface by minimum quality lubrication decrease tool wear [3]. It is
established that the servo oil, cotton seed oil, vegetable oil and soya bean oil has significant effect
on the surface roughness and MRR [4, 5]. It is interesting to note that 40% increase in cutting speed
can be achieved when machining steel with high speed steel tools using water as coolant [6].
Conventional cutting fluids pose environmental and ecological problems such as pollution in the
shop floor, creation of biologically hazardous environment to operators due to bacterial growth,
water pollution and soil contamination during final disposal [7] However, Cutting fluids improve
the efficiency of machining in terms of increased tool life, improved surface finish, improved
dimensional accuracy, reduced cutting force and reduced vibrations [8]. As the tool wear increases
with increase in temperature, the use of cutting fluids reduce the cutting region temperature, and
thereby achieve reduction in tool wear [9, 10]. The present work deals with tool wear analysis and
comparative study of coated and uncoated carbide tool inserts in machining EN24 and SS316L in
dry and wet environments using different lubricant mixtures at different cutting conditions. .
Experiment Requirements
EN24 and SS316L are selected as work piece materials, the compositions of which are presented in
Table 1. The tool inserts used for the proposed work are CNMG 120404 (Uncoated), CNMG
120408 (Uncoated) and CNMG 120408 (Coated)*. The tool holder used is PSBNR 2525 M12. Both
work piece materials are of Ø 60 mm diameter and 380 mm long.
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Applied Mechanics and Materials Vols. 813-814 405
Experiments are carried out, surface roughness is measured by Mitutyo’s surface roughness tester
and tool wear is measured by tool maker’s microscope. The results are shown in Table 4 below
along with the S/N Ratio values obtained thorugh ANOVA Analysis.
Table 4 Details of Output Variables and S/N Ratio
Surface Tool Surface Tool
Trials
Trials
Roughness Wear S/N Roughness Wear S/N
Material Material
(Ra ) [µm] [mm] Ratio (Ra ) [µm) [mm] Ratio
Interaction Plots:
Interaction Plots are plotted for EN24 and SS316L selecting tool wear and surface roughness as
main variables, and associate variables as cutting speed, feed rate, depth of cut and environment.
Fig. 2 and Fig. 3 shows the interaction plots for tool wear and surface roughness for EN24 and
SS316L.
Results inferred from Interaction Plots of EN24: Surface roughness value is low, with second
type of environment with cutting speed of 179.07m/min, feed rate of 0.1mm/rev, depth of cut of
0.5mm, with coated carbide insert of 0.8mm radius. Similarly surface roughness value is observed
to be low with first environment, with 84.82 m/min of cutting speed, feed rate of 0.05mm/rev, and
depth of cut of 1mm with uncoated carbide insert of 0.4mm radius. Tool Wear is observed low with
environment three with a cutting speed of 122.52m/min, feed rate of 0.1mm/rev, and depth of cut of
1 mm with a coated carbide insert of 0.8mm radius. Similarly Tool Wear is very low with
environment one, with cutting speed of 179.07m/min, feed rate of 0.075mm/rev, depth of cut of
0.5mm with uncoated carbide insert of 0.4mm radius. Combination of both tool wear and surface
roughness is observed low with environment three with cutting speed of 122.52m/min, feed rate of
0.1mm/rev, depth of cut of 1mm, and with uncoated carbide insert of 0.4mm radius.
Results inferred from Interaction Plots of SS316L: Surface roughness value is low, with second
type of environment with a cutting speed of 179.07m/min, feed rate of 0.05mm/rev, depth of cut of
0.75mm, with uncoated carbide insert of 0.4mm radius. Similarly surface roughness value is low
with first environment with 84.82 m/min of cutting speed, feed rate of 0.1mm/rev, depth of cut of
0.50mm with uncoated carbide insert of 0.8mm radius. Tool Wear is also observed low with
environment three with 122.52m/min, feed rate of 0.05mm/rev, depth of cut of 0.5mm with
408 Advances in Mechanical Engineering
uncoated carbide insert of 0.4mm radius. Similarly Tool Wear is very low with environment one
with cutting speed of 179.07m/min, feed rate of 0.050mm/rev, depth of cut of 1mm with coated
carbide insert of 0.8mm radius. Combination of both tool wear and surface roughness is observed
low at environment three with cutting speed of 122.52m/min, feed rate of 0.05mm/rev, depth of cut
of 0.5mm, and with uncoated carbide insert of 0.4mm radius.
Fig. 2 Interaction Plot for Tool Wear (Material 1- EN-24, Material 2- SS316L: Environment 1-
Dry, Environment 2- Water+Grease+Oil, Environment 3- Graphite+Grease+Oil,)
1 2 3 0.050 0.075 0.100 0.400 0.800 0.801
2.4 Material
1
1.8 2
Material
1.2
2.4 Environment
1
1.8 2
Environment
3
1.2
2.4 Cutting
Speed
1.8
Cutting Speed 84.82
122.52
1.2
179.07
2.4 Feed
Rate
1.8 0.050
Feed Rate
0.075
1.2
0.100
2.4 Depth
Of Cut
1.8
Depth Of Cut 0.50
0.75
1.2
1.00
2.4 Insert
Radius
1.8
Insert Radius 0.400
0.800
1.2
0.801
1 2 84.82 122.52 179.07 0.50 0.75 1.00
Conclusions
• Generally it is observed that a water miscible fluid made up of water, grease and oil performed
better in terms achieving good surface finish than other type of fluids. A new type of lubricant
mixture made up of graphite, grease and oil also produced better results as equally to the water
miscible fluid.
• In the case of EN24, tool wear and surface roughness together is observed low with cutting
fluid made up of graphite, grease and oil with cutting speed of 122.52m/min, feed rate of
0.1mm/rev, depth of cut of 1mm, and with a uncoated carbide insert of 0.4mm radius.
• In the case of SS316L also, tool wear and surface roughness together is observed low with
cutting fluid made up of graphite, grease and oil with cutting speed of 122.52m/min, feed rate
of 0.05mm/rev, depth of cut of 0.5mm, and with uncoated carbide insert of 0.4mm radius.
• The results declared may be generalized to a considerable extent while working on EN24 and
SS 316L which are most commercially used over decades in metal cutting industry. The study
is limited to the range of values of the specified cutting parameters.
References
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