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Abstract Machining parameters has an important factor on tool wear and surface finish, for
that the manufacturers need to obtain optimal operating parameters with a minimum set of
experiments as well as minimizing the simulations in order to reduce machining set up costs.
The cutting speed is one of the most important cutting parameter to evaluate, it clearly most
influences on one hand, tool life, tool stability, and cutting process quality, and on the other
hand controls production flow. Due to more demanding manufacturing systems, the
requirements for reliable technological information have increased. For a reliable analysis in
cutting, the cutting zone (tip insert–workpiece–chip system) as the mechanics of cutting in this
area are very complicated, the chip is formed in the shear plane (entrance the shear zone) and
is shape in the sliding plane. The temperature contributed in the primary shear, chamfer and
sticking, sliding zones are expressed as a function of unknown shear angle on the rake face
and temperature modified flow stress in each zone. The experiments were carried out on a
CNC lathe and surface finish and tool tip wear are measured in process. Machining
experiments are conducted. Reasonable agreement is observed under turning with high depth
of cut. Results of this research help to guide the design of new cutting tool materials and the
studies on evaluation of machining parameters to further advance the productivity of nickel
based alloy Hastelloy - 276 machining.
1. Introduction
Increasing the productivity and the quality of the machined parts are the main challenges of
manufacturing industry. Modern cutting tools allow cutting at high speeds, thus increasing the volume
of chips removed per unit time and this objective requires better management of the machining system
corresponding to cutting tool-machine tool-workpiece combination to go towards more rapid metal
removal rate. Exploring higher cutting speed depends to a greater extend on the cutting tool materials
[1]. General information on operating parameters employed when turning Nickel based alloys are
available in both academic [2-5] and industrial literatures [6, 7]. From the very beginning, development
of an adequate predictive theory of the process was of a major concern for all researchers. In relation to
machining operations with defined cutting edges, workpiece surface integrity aspects when turning
Inconel 718 with coated carbide cutting tools [8, 9]. Due to their high temperature strength and high
corrosion resistance, nickel based alloys are used for engines for commercial and military aircraft and
space engines. Is considered by machinists one of the most challenging areas. This is due to a complex
of material properties [10,11] namely: low thermal conductivity leading to increased temperatures at
the tool point rake face, work-hardening tendency during machining, high thermal affinity to tool
2. Experimental procedure
The machining tests were performed by single point. A CNC turning machine OKUMA CNC turning
machine supported with Spindle Drive motor 11 KW and 6000 Rpm maximum speed. Z- axis Simens
AC Servo motor 8 Nm and X- axis Simens motor 6 Nm as shown in Figure 1.
Figure 1. CNC machine used in experiments
The workpiece of nickel based Hastelloy – 276 specimens were 300 mm long and 50 mm diameter.
The chemical compositions of the workpiece materials as [Ni:57%; Co:1.62%; Cr:15.44%;
Mo:15.34%; Fe:5.43%; W3.67%; V:0.41%; Mn:0.52%; C:0.004%; Others (Si<0.02%; P-0.005%;
S<0.01%)] and the physical compositions are given in table 1.
Table 1. Physical properties
Dynamic
Electrical
Thermal
Specific
Density
modulus
of
Resistively
conductivity
heat
elasticity
3
8.89
g/cm
1.3
µ
Ω
–
m
229
MPa
10.2
W/m.K
427
J/Kg.K
Ceramic insert tools used for machining nickel based Hastelloy C-276 as shown in Table 2.
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CAMAN IOP Publishing
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043 doi:10.1088/1757-899X/17/1/012043
Table 2. Insert tools and holders used during experiments.
No
Insert
material
Tool
insert
code
Tool
holder
code
3
RNGN
120400E
CRSNR
2525M
12-‐ID
4
Ceramic
SNGN
120412E
SNGN
120412E
5
CNGN
120408
E
CCLNR
2525M
12-‐4
Surface roughness measurement was carried out on the machined surfaces using a Hand – held
Roughness Tester TR200 instrument. Three measurements were made on the each surface. The worn
cutting tools were also examined under a Philips XL 30 ESEM type scanning electron microscope
(SEM).
2.1. Design of experiment
Response surface methodology (RSM) is used to find a combination of factors which gives the optimal
response. RSM is actually a collection of mathematical and statistical technique that is useful for the
modeling and analysis of problems in which a response of interest is influenced by several variables
and the objectives is to optimize the response [18]. There are essentially two main types of designs
experiments which are based on response surface analysis as follows:
Both of these methodologies require a quadratic relationship between the experimental factor and the
responses. In this paper the BBD has been chosen as shown in Figure 2.
Figure 2. The 3N full factorial
The levels of independent variables and coding identifications used in this design are presented in
Table 3.
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CAMAN IOP Publishing
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043 doi:10.1088/1757-899X/17/1/012043
Table 5 shows the experimental conditions and results obtained using ceramic inserts. All of the
turning tests were run dry. Box- Behnken Design is normally used when performing non-sequential
experiments. That is, performing the experiment only once. These designs allow efficient estimation of
the first–order coefficients. Because Box-Behnken Design has fewer design points, they are less
expensive to run than central composite designs with the same number of factors. Box-Behnken Design
do not have axial points, thus can be sure that all design points fall within the safe operating. Box-
Behnken Design also ensures that all factors are never set at their high levels simultaneously [19].
Figure 3 shows the 3N full factors Box-Behnken. Preliminary tests were carried out to find the suitable
cutting speed V, feed rate f, depth of cut d and approach angle K as shown in Table 4. Every one passes
(one pass is equal to 20mm), the cutting test was stopped. The same experiment has been repeated for 3
times to get more accurate result.
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CAMAN IOP Publishing
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043 doi:10.1088/1757-899X/17/1/012043
Figure 3. Main Effects Plot (data means) for Exp. surface roughness Ra (um)
The proposed linear equation is valid only for cutting ceramic tools with a (-6) rake angle within the
cutting conditions range used in the experimentation. Figure 4 shows the plot of experimental surface
roughness versus predicted surface roughness from eq. (1) it is clear that the predicted values are in
good agreement with the experimental readings. This indicates that the obtained linear model is useful
to be the empirical modal for selecting cutting speed values.
Surface
roughness (µm)
(No. of Exp.)
Figure 4. Prediction of cutting force with experimental cutting force.
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CAMAN IOP Publishing
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043 doi:10.1088/1757-899X/17/1/012043
Surface roughness
(µm)
Cutting speed
(m/min)
Depth of cut (mm)
Figure 5. Surface roughness in the cutting speeds - depth of cut plane.
Surface roughness
(µm)
Cutting speed
(m/min) Nose radius (mm)
Figure 6. Surface roughness in the cutting speeds - nose radius plane.
Surface roughness
(µm)
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CAMAN IOP Publishing
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043 doi:10.1088/1757-899X/17/1/012043
Figure 8. Flank wear in the cutting speed – feed rate plane for 0.5 mm depth of cut and 0.8 mm nose
radius.
Figure 9. Chipping wear in the cutting speed – feed rate plane for 1 mm depth of cut and 1.2 mm nose
radius.
Figure 10. BUE in the cutting speed – depth of cut plane for 0.15 mm feed rate and 0.8 mm nose
radius.
Tool wear type while cutting the Hastelloy - 276 is chipping wear at the line depth of cut due to high
thermal, high work hardness, high strength of the work-piece and abrasive particles. Furthermore; flank
wear, chipping and severe damages are the causes of tool wear.
The inserts were tested by cutting Hastelloy - 276 under different cutting parameters as listed in Table
3. For each experiment, Reference flank wear value VBB = 0.3 mm is chosen as wear criterion
according to International Standard Organization. A cutting tool was rejected and further machining
was stopped based on one or a combination of the following rejection criteria in relation to ISO
Standard 3685 for tool life testing:
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CAMAN IOP Publishing
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043 doi:10.1088/1757-899X/17/1/012043
Ceramic tool tips used to machine the nickel based Hastelloy-276 workpiece material were examined
by The SEM images of the worn cutting edges. It is seen from these images that wear predominantly
occurred in two regions during the tests: at the depth of cut line and the nose. However, wear at the
nose radius of cutting edge directly influences the machined surface finish since the nose edge is in
direct contact with the newly machined surface. However, further increasing in the depth of cut
increases the extent of tool wear.
In this study, flank wear and excessive chipping wear, which are important problems reducing
tool life, are mainly observed in the machining experiments ceramic tools. It is considered that the tools
having negative and larger approach angle with bigger nose radius must be used in order to solve
chipping wear problem.
4. Conclusion
Turning tests were performed on Nickel based Hastelloy C-276 using two different inserts of ceramic
cutting tools. The influences of cutting speed, tool inserts type and workpiece material were
investigated on the machined surface roughness. Based on the results obtained, the following
conclusions can be drawn:
1. Cutting speed was found to have a significant effect on the machined surface roughness values.
2. Influence of Depth of cut was found to affect the surface roughness when it increased from
medium to high value.
3. Interaction of cutting speed and depth of cut influence the surface roughness and tool wear and
generating BUE in the low to medium speed.
4. Nose radius wear, evidenced by the SEM examinations, were found to be responsible for the
surface roughness values.
5. Round insert found to produce better surface roughness associated with decreasing the depth of
cut and increasing the cutting speed.
6. Feed rate uneducated the surface finish for that it recommended to increase the feed rate with
cutting speed and low to medium depth of cut.
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