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European Journal of Scientific Research

ISSN 1450-216X Vol.38 No.2 (2009), pp.180-188


© EuroJournals Publishing, Inc. 2009
http://www.eurojournals.com/ejsr.htm

Tool Wear and Surface Finish Investigation in High Speed


Turning Using Cermet Insert by Applying Negative Rake Angles

Erry Yulian T. Adesta


Department of Manufacturing and Materials Engineering, Faculty of Engineering
International Islamic University Malaysia, Jalan Gombak
Kuala Lumpur 53100 Malaysia
E-mail: eadesta@iiu.edu.my
Tel.: +60361964452; Fax: +60361964477

Muhammad Riza
Department of Manufacturing and Materials Engineering, Faculty of Engineering
International Islamic University Malaysia, Jalan Gombak
Kuala Lumpur 53100 Malaysia

Muataz Hazza
Department of Manufacturing and Materials Engineering, Faculty of Engineering
International Islamic University Malaysia, Jalan Gombak
Kuala Lumpur 53100 Malaysia

Delvis Agusman
Department of Mechanical Engineering, Faculty of Engineering
Universitas Tarumanagara
Jalan Let. Jend. S. Parman no. 1 Jakarta
Indonesia 11440

Rosehan
Department of Mechanical Engineering, Faculty of Engineering
Universitas Tarumanagara
Jalan Let. Jend. S. Parman no. 1 Jakarta
Indonesia 11440

Abstract

Cermets are not new, in spite of their growing use in recent years. This is due more
to the improvement of the cermet grades, improved stability, speeds and conditions as well
as the trend towards near-to-finish workpiece blanks. This experiment is to investigate tool
wear and surface roughness under different rake angles and different cutting speed.
Experiments were carried out by using cermet (CT5015). Different rake angles have been
applied in the experiments which are 0, -3. -6, -9 and -12 respectively and cutting speed
1000 m/minute and feed rate 800 mm/minute have been applied. For every single pass of
cutting, surface roughness of workpieces were measured by surface roughness tester. The
experimental results showed that by increasing negative rake angles the higher wear
occurred shorter duration of tool life and poor surface finish. The different between high
Tool Wear and Surface Finish Investigation in High Speed Turning Using Cermet
Insert by Applying Negative Rake Angles 181

speed and conventional speed was also observed in this experiment. High speed turning
gives shorter tool life, high wear rate but finer surface finish than conventional one.

Keywords: Cermet, High Speed Turning, Negative Rake Angle, Surface Roughness, Tool
Wear.

1. Introduction
The challenge of modern machining industries is focused mainly on the achievement of high quality, in
terms of work piece dimensional accuracy, surface finish, high production rate, less wear, on the
cutting tools, economy of machining in terms of cost saving and increase the performance of the
product with reduced environmental impact (Thamizhamanii, 2006).
Development of new cutting tool materials and availability of machine tools with high
rotational speeds have made it possible to increase material removal rate. But at a high cutting speed
tool wear occurs more intensively and causes the requirement of frequent tool changing. Again, tool
changing time increases machine downtime and reduce the productivity of machining (Khan, 2006).
Advances in ceramic processing technology have resulted in a new generation of high performance
ceramics cutting tools exhibiting improved properties such as fracture strength, toughness, thermal
shock resistance, hardness and wear resistance. Aluminum oxide is widely used as ceramic cutting tool
and it is strengthened by addition of particles like zirconium oxide, titanium carbide and titanium
nitride to improve their properties (Senthilkumar et al, 2003).
In order to produce any machine part at a certain quality by any metal removal technique,
cutting parameters should be arranged properly. Dependent upon workpiece material and geometry to
be desired, cutting forces have important influence on determining of machining cost related to cutting
speed, feed rate, undeformed chip thickness, cutting tool material, geometry and rake angle (Gunay,
2004).

2. Previous Research
Different researchers have carried out investigations on tool wear and tool life at high cutting speeds. A
collection of papers related to this topic but little empirical studies have been conducted on the issue of
negative rake angle.
Kilickap et. al. (2005) investigated tool wear and surface roughness in machining of
homogenized SiC-p reinforced aluminium metal matrix composite. They found that tool wear was
mainly affected by cutting speed, increased with increasing cutting speed. Tool wear was lower when
coated cutting tool was used in comparison to uncoated one. Surface roughness influenced with cutting
speed and feed rate. Higher cutting speed and lower feed rates produced better surface quality.
Khan et. al. (2006) illustrated capabilities of cermets tools for high speed machining of
austenitic steel. They found that when cermet inserts were used for finishing cuts, very fine surface
were produced. However, when used for roughing cuts, they tended to fracture unpredictably rather
than having gradual flank wear. The similar view of point was expressed by Thamizhmanii and Hasan
(2006) in their research in illustrated analyses of roughness, forces and wear in turning gray cast iron.
They found that the surface roughness from various tests shows a decrease in value at higher cutting
speed and feed rate.
Thamizhmanii et. al. (2007) in their proceedings titled tool wear and surface roughness in
turning AISI 8620 using coated ceramic tool explained that surface roughness decreased when the
cutting speed was increased and tool wear was not noticeable for a few tests. It increased rapidly at
higher cutting speed, feed rate, higher depth of cut and increased inn time. The flank wear, crater wear
and nose wear were measured.
182 Erry Yulian T. Adesta, Muhammad Riza, Muataz Hazza, Delvis Agusman and Rosehan

Tool life of alumina ceramics inserts is not satisfactory when machining nodular cast iron. In
the speed range 364 – 685 m/min, maximum tool life achieved was only about 1.5 min. Surface finish
was found to be almost constant for the same flank wear, vibration during cutting decrease as the speed
increases. At low depth of cut, vibration remains almost constant with the increase of flank wear
(Ghani et al, 2002).
Feng (2001) illustrated an experimental study of the impact of turning parameters on surface
roughness. It featured the following contributions. First, the depth of cut does not worsen the surface
microstructure of the material and the dimensional and geometric accuracy. Second, in addition to
feeds, nose radius, work materials and speeds, the tool point angle has a significant on the observed
surface roughness. Third, strong interactions were observed among the above turning parameters. Most
significant interactions were found between work materials, point angle and speed.
Mustafa Gunay et al. (2005) investigated experimental investigation of the cutting tool rake
angle on main cutting force. They found that main cutting force was reduced by increasing rake angle
in positive and was increased by increasing rake angle in negative values. Main cutting force for all
cutting speeds was high for negative rake angles.
Mustafa Gunay (2008) in his research investigation of the interaction between the surface
quality and rake angle in machining of AISI 1040 steel revealed that negative rake angle resulted in
poor surface quality and rake angle is dominant parameter associated with the surface roughness.

3. Research Method
The workpiece material used in the present works was steel with 0.44% C. The diameter and length of
the workpiece were 80 and 150 mm, respectively. Cermet tool inserts (CT5015) were used in the
present work with rake different rake angles which are 0o, -3o, -6o, -9o and -12o. The cermet tools were
mechanically clamped to the tool holder.
The experiments were conducted on lathe model Power Path 15 HS – High Speed Version
(spindle ASA A 2-5”). Metal cutting was performed at cutting speeds 1000 for high seed turning and
300 m min-1 for conventional speed. Feed rate for high speed and conventional speed were 800 and
240 mm min-1, respectively. Depth of cut tried was 0.5 mm for every cutting process. All the process
and parameters were programmed in 2 set of NC programming. Each inserts of cutting tool had 6 edges
(3 on each side). Thus each insert was capable of performing 6 trials.

4. The Results and Discussions


Results of the experiments were analyzed with assist with the photographs taken by the SEM. The
photographs were taken with high magnification in order to obtain a clear view of worn-out cutting
edges. Discussions on the results have been set out in the following paragraphs.

4.1. Tool Life and Tool Wear


4.1.1 Tool Life
This section consisting of the cermet insert analysis of tool life and tool wear results when machining
performed. The variation of rake angles has been applied in this experiment. The results of tool life are
graphically shown in fig. 1. From the fig.1 bellow, it is evident that tool life of high speed turning is
lower than conventional machining. The higher cutting speed the shorter tool life resulted.
Variations of tool life with cutting speed for the workpiece having 1000 m/min and 300 m/min.
in speed are shown in Fig.1. The figure shows that the cermet tool life is opposite with cutting speed.
(Bouzid, 2006) also reported that the tool wear increases rapidly when the coating layer is removed
from the tool surface and the wear at the failure varies with the cutting speed. Similarly, observations
were also reported by Khan et. al. (2002) that the life of cermet tools is very long while machining with
low cutting parameters. At low cutting parameters a gradual flank wear is observed. But as the cutting
Tool Wear and Surface Finish Investigation in High Speed Turning Using Cermet
Insert by Applying Negative Rake Angles 183

speed is increased up to a certain limit, a brittle fracture occurs at the cutting edge rather than a gradual
flank wear and the depth of the cracks on the cutting edge increases rapidly resulting in a catastrophic
failure of the tool. Khan et al. (2006) was also reported that when the cutting speed is comparatively
low, the size and depth of the crack on the flank is very small. Crack grows rapidly at higher cutting
speeds. The cutting force on the tool edge increases as the cutting speed is increased. Though cermet
tools have high hot hardness and wear resistance, they have low fracture toughness. As a result tool
wear intensifies at a high cutting speed. According to experiments, it is noted that the life of insert in
conventional machining is 9.7 times longer than high speed turning.

Figure 1: Tool life of high speed turning vs conventional machining

Through fig. 1 obviously can be seen that at high speed turning circumstance wear is decrease
as more negative rake angles applied. As negative value of rake angles increase the force occurred at
cutting tool insert also increase. It is agreeable with Gunay (2005) that increasing of contact area in
negative angles and machining chip volume influence considerably cutting force and heat generation
too much. High cutting force and excessive heat occurred cause excessive wear which lead to reduce
the duration of tool life. As noted that heat occurred in this circumstance not only affected by force act
to insert tools but also produce by high speed rotation of workpiece as explained above.
According to Khan (2006), under heavier cutting conditions the rate of heat generation at the
cutting zone is high, but thermal conductivity of cermets tools is very low. As a result the temperature
at the cutting edge rises to a high level which ultimately causes tool failure. He was also observed in
his research that the other reason of tool failure is low fracture toughness of cermet tools.

4.1.2. Tool Wear


The graph at fig 2 shows that tool wear on high speed turning is higher than conventional one. The
ware from both of speeds increase gradually as time goes. Temperature was claimed as the reason of
tool wear in this experiment. The tool wear was affected by temperature. The higher temperature the
great wear occurred. It is agreeable what has found by Lin, (2007) that the wear is related to cutting
temperature.
184 Erry Yulian T. Adesta, Muhammad Riza, Muataz Hazza, Delvis Agusman and Rosehan

The flank wear in this experiment can be seen obviously when high speed turning applied.
Through fig. 2 can be observed that tool wear is increase rapidly as cutting speed and rake angle
increase obviously. When machining at high speed (1000 m/min) with feed rate 800 mm/min. at 0o
rake angle the wear is 0.056 mm then increase dramatically to 0.083 mm at -12o rake angle. But flank
wear start with very low which is 0.028 mm at rake angle 0o then increase very slowly and going down
at 0.018 at rake angle 12o when machining at conventional speed (300 m/min).

Figure 2: Tool wear insert development under different rake angle in two different machining conditions

Another fact known from the graph that the higher cutting speed the significant wear is
occurred. In another word, cermet tools are very sensitive to cutting speed. When the cutting speed is
comparatively low (300 m/min.) with feed rate 240 mm/min, the flank wear is very small after
machining. According to Ozses (2002), low feed rate results in better surface finish. Oppositely, wear
grows rapidly at higher cutting speeds (1000 m/min.). This is occurred because the cutting force on the
tool edge increases as the cutting speed is increased. Similar viewpoint was proposed by Gunay et al.
(2005) who founded that negative rake angle will increase the cutting force and therefore high heat will
be generated. It was also found by Khan et al. (2002) that the life of cermet tools is very long while
machining with low cutting parameters. At Low cutting parameters a gradual flank wear is observed.
But as the cutting speed is increased up to certain limit, a brittle fracture occurs at the cutting edge
rather than a gradual flank wear.
Besides that, from the fig. 2 also found that tool wear increases as negative rake angle is
increased. This condition was occurred to both machining process. It is noted that on high speed
turning, tool worn more than conventional one. It is due to the force produced by increasing negative
rake angle is increased. It was observed by (Shaw, 1984), (Jaspers et al 1999), (Rao, 1995), (Huang,
1999). Tool forces usually rise as the tool is worn, the clearance angle is destroyed, and the area of
contact on the clearance face is increased by flank wear (Black and Trent, 1989). Increasing of contact
area in negative angles and machining chip volume influence considerably cutting forces and heat
generation too much (Gunay, 2003). As consequently, temperature rise and as generally known that it
affect to tool wear.

4.2. Surface Finish


The values of rake angles against surface roughness at different cutting speed are shown in fig. 3. It is
observed that cutting speed has impact to surface roughness. The experiments were proof that by
increasing cutting speed and feed rate will produce finer surface finish. It is noted that range of
Tool Wear and Surface Finish Investigation in High Speed Turning Using Cermet
Insert by Applying Negative Rake Angles 185

roughness in high speed turning is between 1.40 to 1.72 μm and range of conventional machining is
wider which covered area between 1.37 to 1.90 μm. Thamizhmanii (2006) and (2007) was found
during his experiment that by increasing the cutting speed and feed rate, the Ra value was encouraging
and reduced. The similar view point was proposed by Kılıçkap (2005).

Figure 3: Surface finish under different rake angles in two different machining conditions

Through the graph, we can observe that rake angle has impact to surface roughness. As
negative rake angle increase the surface roughness is increase. In other word, the surface finish of
workpiece is rougher by increasing negative rake angle. Trend of roughness is tend to increase can be
seen at both of cutting speed under different negative rake angle. At the conventional speed, Ra is
started from 1.38 μm at rake angle 0 and finish at rake angle -12 with Ra is 1.78 μm. The similar
condition appeared in high speed turning which the wear is tent to increase. It begins with 1.39 μm at 0
rake angles and at -12 rake angle the value of wear is 1.74 μm. Gunay (2008) was found in his research
that negative rake angle resulted in poor surface quality. Those occurred because the wear and crack of
tool insert occurred faster when more negative rake angle applied. Negative rake angles cause larger
contact area cause also higher chip volume, which both result in increased heat generation (Gunay,
2004). Force work in the insert tool was claimed as the reason wear is occurred. As explained by
Gunay (2005) that negative rake angle will increase the cutting force. Tool forces usually rise as the
tool is worn, the clearance angle is destroyed, and the area of contact on the clearance face is increased
by flank wear (Black, 1989). Flank wear causes scratch on the surface of workpiece and finally lead to
poor surface finish. This poor surface quality can be attributed to the higher cutting forces and negative
effect of chip flow on surface with negative rake angle (Thomas, 2003). The other reason is low
fracture toughness of cermet tools as observed by Khan (2006).

4.3. Visualization and Scanning Electron Microscope (SEM) Study


Material surfaces were also examined under the SEM. The analysis was performed to observe tool rate
the machined surface at different rake angles which are 0, -3, -6, -9, and -12. Fig. 4 shows the SEM
micrograph taken within high speed turning and conventional machining at 200X magnification.
Flank and crater wear are the most important measured forms of tool wear. Flank wear is most
commonly used for wear monitoring (Astakov, 2008). The flank wear in this experiment can be seen
obviously when high speed turning (1000 m/min) applied. Further heavier cutting conditions worsen
186 Erry Yulian T. Adesta, Muhammad Riza, Muataz Hazza, Delvis Agusman and Rosehan

the mode of tool failure. (Khan, 2006) observed that a few factors are responsible for catastrophic
failure of cutting edges (fig. 4 (a) – (e)). First, of all, under heavier cutting conditions the rate of heat
generation at the cutting zone is high, but the thermal conductivity of cermet tools is very low. As a
result the temperature at the cutting edges rises to a very high level which ultimately causes tool
failure. The second reason is obviously the low fracture toughness of the cermet tools.
Through fig. 4 (a) – (e) can be observed that tool wear is increase rapidly as cutting speed and
rake angle increase obviously. While, in fig. 4 (f) – (j) show the tool wear at low cutting speed (300
m/min). Through the photo taken with SEM the wear is very low because low temperature produces
during the cutting process.

Figure 4: The SEM micrograph taken within high speed turning and conventional machining at 200x
magnification. Fig. 4.4 (a) – (e) are tool wears under high speed turning at 0, -3, -6, -9 and -12 rake
angles. Fig. 4.4 (f) – (j) tool wears under conventional speed at 0, -3, -6, -9 and -12 rake angles.
Tool Wear and Surface Finish Investigation in High Speed Turning Using Cermet
Insert by Applying Negative Rake Angles 187

5. Summary and Concluding Remarks


From the present analysis and discussion the following conclusions can be drawn:
1. Wear occurred freshly when high speed turning applied in cutting speed. This is due to high
temperature generated in high speed turning and low fracture toughness of cermet tools.
2. At a low cutting speed the life of cermet tools is quite long and the job surface finish is quite
satisfactory. But an increase in cutting parameters is lead to rapid failure of the tools.
3. At low negative rake angles the tool wear is low but the more negative rake angles causing tool
wear is high. This is due to tool forces usually raise as the tool is worn, the clearance angle is
destroyed, and the area of contact on the clearance face is increased by flank wear. As
consequently, temperature rise and as generally known that it affect to tool wear.
4. As negative value of rake angles increase the force occurred at cutting tool insert also increase.
This is lead to excessive heat and wear. As result tool life duration of insert tools were become
short.

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