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Materials Today: Proceedings 5 (2018) 13321–13333 www.materialstoday.com/proceedings

ICMMM - 2017
Influence of Process Parameters on the Machining Characteristics of
Austensite Stainless Steel (AISI 304)
A.P.Junaidha, G.Yuvaraj b*, Josephine Peterc, V Bhuvaneshwarid, Kanagasabapathie,
K. Karthikf
a,b*,c,d,e,f
KPR Institute of Engineering and Technology,Coimbatore and 641047, India

Abstract

Generally Austensite stainless steel are used as most common stainless steel used in various applications because of
easily formable and weldable. But the machining properties of Austensite steel is poor due to inherent properties of low thermal
conductivity and high work hardening. In the present work focused on the machining characteristics such as cutting force
analysis, surface roughness analysis and chip morphology of Austensite stainless steel investigated with the help of turning
operation using uncoated carbide tool, which is processed by four different cutting speeds and three different feeds. Based upon
cutting force, chip morphology and the surface roughness, it is finally concluded that the proper selection and control of process
variables can significantly improve the machining characteristics of AISI 304 austenitic stainless steel.
© 2017 Elsevier Ltd. All rights reserved.
Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).

Keywords: Austensite steel; machining properties; surface roughness; cutting force; Chip morphology

1. Introduction

Stainless steel was generally attributed as being an expensive, high-technology alloy. This made stainless steel
more cost-effective and affordable. H. Chandrasekaran et.al. [1] investigated the notch wear through step turning
which have four austensite steel with cemented carbide material. A.K. Chakrabarti. et.al [2] investigated the
properties of added and unadded austensite steel with acknowledged to the cutting force analysis and chip flow
characteristics and their morphology, the composition influences the machinability. D.O’Sullivan.et.al. [3]
investigate the properties of austenitic alloys with chromium improved the corrosion resitance properties and by
adding nickel increase the hardness. C.J. Novak et.al [4] studied the fabrication of stainless steel through laser
engineering net shaping method and prove the high percentage of chromium increasing the strength in cutting tool.
K.H. Lo.et.al [5] analysed about the characteristics of hardening and ductility of austensite structure, which it is
suitable for machining tool. D. San Martin.et.al [6]studied the austenitic phase transforms into martensite upon
deformation. Martensite so produced offers higher strength as well as toughness owing to the presence of retained
austenite. M. Hattestrand et.al.[7] investigated the change in properties of stainless steel by additional heat

*
Corresponding Author: Tel; +918870207350
Email address: yuvaraj.g@kpriet.ac.in

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Materials Manufacturing and Modelling (ICMMM - 2017).
13322 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333

treatment (hardening and tempering). J. Post.et.al. [8, 9] analysed the approach which improves the ductile strength
and fatigue failure in different proportions of carbide with austensite structure. H. Dong et.al. [10] studied the
unique properties and advantages give raise to wide range of applications for austenitic stainless steels including
Automotive parts, Cookware, Food and beverage equipment, Industrial equipment.
Shreemoy Kumar Nayak.et.al.[11] analysed the ISO P30 grade uncoated cemented carbide cutting tool of cutting
force, surface roughness characteristics. Groover MP [12] investigated the buildup edge formation on the tool when
it made to contact on workpiece at small running speed of 140 rpm. Chromium, molybdenum and other alloying
metals added also decrease machinability of austenitic stainless steels. Agrawal et al.[13] reviewed the cast duplex
austensite steels which influences the cutting speed, surface roughness characteristics. Korkut et al. [14] investigated
the properties of AISI 304 steel having high strength, able to withstand the thermal heat distribution which increases
the cutting force and feed rate. Ibrahim Ciftci [15] studied the single point tool machining characteristics of turning
operations made by AISI 304 and AISI 316 grade austenitic stainless steel specimens by using TiC/TiCN/TiN and
TiCN/TiC.
Swapnagandha et al. [16] studied the effect of chip – tool interface by adding titanium with aluminium alloy
operated at the speed of 1270 rpm in drilling operation, which results in improvement of surface finish. Fernández-
Abia et al. [17] studied about the Behaviour of PVD coatings in the turning of austenitic stainless steels (AlTiSiN,
AlCrSiN, AlTiN and TiAlCrN) and measured tool wear, cutting forces. Jianxin et al. [18] investigated the fatigue
strength and by adding Cr12Mn5Ni4Mo3Al it improves the hardening and corrosion withstand capacity. Hence the
present study is focused on understanding the characteristics of austenitic stainless steel under the dry turning
operation using the uncoated carbide tools. The machining experiments were carried out under the finishing
conditions using four speed variations and three feed variations in external longitudinal turning of AISI 304
austenitic steel bars in terms of cutting forces, surface roughness, tool wear and chip morphology.

2. Experimental plan

DOE process can be divided into three main stages such as shown in figure 1 and the experimental setup shown
in figure 2.

a. Planning stage b. Conducting stage c. Analyzing stage

Fig 1.Methodology followed to find the effect of process parameters on the machining. Fig 2. Experimental set up.

3. EXPERIMENTAL PROCEDURE

The procedure used to find the influence of process parameters on machining characteristics of AISI 304
austenitic stainless steel. With the help of machining parameters namely cutting speed, feed rate and depth-of-cut, it
is easy to find the cutting force analysis, tool wear analysis and surface roughness of work piece and tool.
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3.1. Cutting Tool:

Uncoated tungsten carbide inserts are used for the turning process shown in figure 3. With an ISO designation of
SPUN 12 03 08. Specifications of these inserts are given in Table 1.

Fig. 3. Uncoated tungsten carbide inserts used for the turning process
Single insert tool holder used in the experiments manufactured by WIDIA based upon ISO designation CSBPR
25 25 M12 shown in figure 4. Specifications are given in Table 2.

Fig 4. CSBPR 25 25 M12 single insert tool holder used in the machining experiments

Table 1. Specifications of cutting tool Table 2. Specifications of tool holder

S.No. PARAMETER VALUE S.No. PARAMETER VALUE

1 Weight 0.0075 kg 1 Weight 0.707 kg
2 Cutting Edge Effective Length (LE) 11.9 mm 2 Head Length 30 mm
3 Insert Thickness (S) 3.175 mm
3 Inclination Angle 0 deg
4 Inscribed Circle Diameter (IC) 12.7 mm
4 OrthogonalRake Angle 5 deg
5 Corner Radius (RE) 0.8 mm
5 Shank Height 25 mm
6 Clearance Angle 11 deg
7 Coating Uncoated 6 Shank Width 25 mm
8 Insert Included Angle 90 deg 7 Tool Length 150 mm
9 Cutting Edge Count 4
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3.2. Manufacturing of workpiece

AISI 304 austenitic stainless steel workpiece material has been used. Properties of the material are shown in Table 3.
and Table 4. Respectively.
Table 3. Properties of AISI 304 Austenitic Stainless Steel
S.No. PROPERTIES RANGE
1 Density (g/cc) 8
2 Tensile Strength (Mpa) 505
3 Yield Strength (Mpa) 215
4 Hardness, brinell (BHN) 123
5 Young's Modulus (Gpa) 193 - 200
6 Poisson’s ratio 0.29
7 Shear Modulus (Gpa) 86
8 Melting point 1400 –
14550C
9 Specific Heat Capacity (J/g-0C) 0.5
10 Thermal Conductivity (W/m-K) 16.2

Table 4. Typical composition of AISI 304 samples (Wt. %)

C Cr Silicon Mn Ni P S Fe

Maximum Maximum Maximum Maximum

18-20 Maximum 3 7-9.5 Rest
0.08 2.5 0.5 0.03

Cylindrical bars of length 300 mm and diameter 32 mm used as workpiece for the machining experiment. A
workpiece sample is shown in figure 5.

Fig 5. Sample work piece used for machining experiment

4. TESTS AND RESULTS

4.1. Cutting Force Analysis

In turning operation, Tangential force and axial force plays major role in determining the machinability. Hence,
these are discussed in Table 5. These values are obtained by taking average value of an appropriate region of the
output data obtained from Labview software. Using these values axial cutting forces (Fx) and tangential cutting
forces (Fz) are plotted as a function of cutting speed for different feeds as in figure 6 and figure 7 respectively.
 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333 13325

Table 5. Axial and tangential cutting force values obtained from machining process

Experiment Cutting Speed Feed Depth of Cut Axial Cutting Tangential

No. (m/min) (mm) Force, Cutting Force,
(mm/rev) Fx (N) Fz (N)
1 50 0.05 0.5 543.18 377.60
2 50 0.1 0.5 856.17 562.80
3 50 0.15 0.5 1220.60 644.91
4 100 0.05 0.5 449.17 264.1
5 100 0.1 0.5 777.51 445.13
6 100 0.15 0.5 1147.3 498.90
7 150 0.05 0.5 331.2 191.99
8 150 0.1 0.5 689.26 354.23
9 150 0.15 0.5 1042.74 421.77
10 200 0.05 0.5 243.82 152.18
11 200 0.1 0.5 641.63 256.77
12 200 0.15 0.5 959.22 392.04

1400
Axial Cutting Force,

1200
1000
Fx (N)

800
600
400
200
0
50 100 150 200
Cutting Speed, Vc (m/min)
Fig 6. Axial cutting forces of TnC tools in dry turning of AISI 304 at different cutting speeds and feeds (test conditions: depth of cut=0.5mm,
machining length=30mm.)

700
Tangential Cutting

600
Force, Fz (N)

500
400
300
200
100
0
50 100 150 200
Cutting Speed, Vc (m/min)
Fig 7. Tangential cutting forces of uncoated tungsten carbide tools in dry turning of AISI 304 at different cutting speeds and feeds (test
conditions: depth of cut=0.5mm, machining length=30mm.)
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4.2. Surface Roughness Analysis

Surface texture is an important factor to determine the machinability of a material. In post-machining stage, the
lower surface roughness (Ra) for a machined surface means the material is having better machinability. Depends
upon cutting conditions, surface quality is obtained.

4.2.1. Test Procedure of Surface Roughness:

The test procedure to measure surface roughness is explained. By this method, Ra, Rq, Rz and Rmax values are
obtained for each case.
Ra - The Mean Roughnes
Table 6. shows the different ranges in surface roughness values with cutting speed for the machined AISI 304
austenitic steel workpieces. It is clear that cutting speed has the major effect on surface roughness. Observed
maximum roughness value is at the cutting speed of 50 m/min. As the speed increases surface roughness reduces to
certain value and then it increases. Minimum values of surface roughness values are obtained at the cutting speed
150 m/min and feed rates of 0.05 and 0.1 mm/rev. It can be also noted that surface roughness increases with an
increase in feed.
1.8
Surface Roughness, Ra

1.6
1.4
1.2
1
(µm)

0.8
0.6
0.4
0.2
0
50 100 150 200
Cutting Speed, Vc (m/min)
Fig 8. Variation in surface roughness values with cutting speed for the machined AISI 304 workpieces for different feeds (test conditions:
depth of cut=0.5mm, machining length=30mm.)
From the figure 8, it is clearly seen that surface roughness increases with increase in feed which is in line with the
cutting speed. Also, increase in feed, friction between work piece and tool interface increases.

Table 6. Surface roughness (Ra) values of workpieces obtained.

Experiment Cutting Speed Feed Depth of Cut Surface
No. (m/min) (mm/rev) (mm) Roughness,Ra (µm)
1 50 0.05 0.5 1.172
2 50 0.1 0.5 1.3
3 50 0.15 0.5 1.552
4 100 0.05 0.5 1.002
5 100 0.1 0.5 1.14
6 100 0.15 0.5 1.46
7 150 0.05 0.5 0.794
8 150 0.1 0.5 0.827
9 150 0.15 0.5 1.439
10 200 0.05 0.5 0.866
11 200 0.1 0.5 0.99
12 200 0.15 0.5 1.5
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4.3. Tool Wear Analysis

Flank wear is most common in machining of hard and difficult to machine materials. So, the present study
mainly focuses on flank wear even though crater wear images are also shown in figure 9.

a) Flank wear at feed = 0.05 mm/rev. b) Crater wear at feed = 0.05 mm/rev

c) Flank wear at feed = 0.1 mm/rev. d) Crater wear at feed = 0.1 mm/rev

e) Flank wear at feed = 0.15 mm/rev. f) Crater wear at feed = 0.15 mm/rev

Fig. 9. Flank wear and crater wear at cutting speed 50 m/min.

Both flank wear and crater wear are noted in the experiment. Figures 9, 10, 11, 12 shows microscopic images of
flank wear and crater wear on the cutting tool formed at the cutting speed of 50 m/min, 100m/min, 150 m/min and
200m/min respectively (maximum and minimum flank wear values are shown).
13328 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333

a) wear at feed = 0.05 mm/rev. b) Crater wear at feed = 0.05 mm/rev

c) Flank wear at feed = 0.1 mm/rev. d) Crater wear at feed = 0.1 mm/rev

e) Flank wear at feed = 0.15 mm/rev. f) Crater wear at feed = 0.15 mm/rev
Fig. 10. Flank wear and crater wear at cutting speed 100 m/min.

It is observed from the images rake surface was not affected as the turning operation. But flank surface have notable
wear. Figure 11 shows the ranges of maximum flank wear with cutting speeds for different feeds.
 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333 13329

a) Flank wear at feed = 0.05 mm/rev. b) Crater wear at feed = 0.05 mm/rev

c) Flank wear at feed = 0.1 mm/rev. d) Crater wear at feed = 0.1 mm/rev

e) Flank wear at feed = 0.15 mm/rev. f) Crater wear at feed = 0.15 mm/rev

Fig 11. Flank wear and crater wear at cutting speed 150 m/min.
13330 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333

a) Flank wear at feed = 0.05 mm/rev. b) Crater wear at feed = 0.05 mm/rev

c) Flank wear at feed = 0.1 mm/rev. d) Crater wear at feed = 0.1 mm/rev

e) Flank wear at feed = 0.15 mm/rev. f) Crater wear at feed = 0.15 mm/rev

Fig. 12. Flank wear and crater wear at cutting speed 200 m/min.
 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333 13331

4.3. CHIPS ANALYSIS:

The results from the chip morphology analysis corroborate the trends observed in other machinability
evaluations such as tool wear and surface texture analysis. Morphology of chips obtained at different cutting speeds
and feeds are presented in Table 7.

Table 7. Morphology of chips obtained at different cutting speeds and feeds

For the cutting speed of 50 m/mim & feed For the cutting speed of 50 m/mim & feed For the cutting speed of 50 m/mim & feed
of 0.05mm of 0.1mm of 0.15 mm

For the cutting speed of 100 m/mim & feed For the cutting speed of 100 m/mim & feed For the cutting speed of 100 m/mim &
of 0.05mm of 0.1mm feed of 0.15mm

For the cutting speed of 150 m/mim & feed For the cutting speed of 150 m/mim & feed
For the cutting speed of 150 m/mim & feed of 0.15mm
of 0.05mm of 0.1mm

For the cutting speed of 200 m/mim & feed For the cutting speed of 200 m/mim & feed For the cutting speed of 150 m/mim & feed
of 0.05mm of 0.1mm of 0.15mm

It can be seen that continuous chips are obtained at all cutting conditions. This is due to the high ductility of the
material. Two different kind of chips obtained are coiled and uncoiled. Figure 13 shows a graphical representation
of images of chips obtained with cutting speed along X axis and feed along Y axis.
13332 A.P.Junaidh et al. / Materials Today: Proceedings 5 (2018) 13321–13333

Fig 13. Graphical representation of chips obtained when machining AISI 304 workpieces at various cutting speeds and feeds (test conditions:
depth of cut=0.5mm, machining length=30mm.).

The temperature variation across the thickness of chip is the main reason why it gets coiled. At lower feed of 0.05
mm/rev coiled chips are obtained at all cutting speeds. This is because, at lower feeds, the chip thickness is low and
the temperature variation is high. Therefore uncoiled chips are obtained for the feeds of 0.1 mm/rev and 0.15
mm/rev at all cutting speeds. Since coiled chips are more delicate and easier to handle, this suggests using a lower
feed value for machining of AISI 304.

5. CONCLUSIONS

In the present study, the effect of process parameters like cutting speed and feed on the machining
characteristics of AISI 304 austenitic stainless steel is investigated in terms of cutting forces analysis, surface
roughness, tool wear analysis and chip morphology. External longitudinal turning under dry cutting condition using
uncoated tungsten carbide tool is carried out as the machining process. Four different cutting speeds (50 m/min, 100
m/min, 150 m/min and 200 m/min) and three feed values (0.05 mm/rev, 0.1 mm/rev and 0.15 mm/rev) under
constant depth of cut (0.5 mm) are used in the experiment. Cutting forces measured using dynamometer during the
machining process and chips are collected. Surface roughness of the machined workpieces measured and chip
morphology is analysed.
Following conclusions can be drawn
 If cutting speed increases, cutting forces decreases where as it increases with feed.
 With increasing cutting speed, surface roughness values decreased.
 Tool wear found increasing with an increase in speed but it shows decreasing behaviour with an increase in feed.
Coiled chips are obtained at lower feed value, which are easier to handle.
 From this study, it is concluded that the proper selection and control of process variables can significantly
improve the turning operation performance of AISI 304 austenitic stainless steel.
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