“INVESTIGATION OF CUTTING FORCE AND TOOL

WEAR BEHAVIOUR IN DRY TURNING OF INCONEL

625”

By

DEEP D. VADALIA

ENROLLMENT NO.: 130180708005

Under the Guidance of

Prof. ALPESH MAKWANA

Assistant Professor, Mechanical Engineering Department

Government Engineering College, Dahod

A Thesis Submitted To

Gujarat Technological University

In Partial Fulfillment of the Requirements for Degree of

Master of Engineering in

Mechanical Engineering Department

(CAD/CAM)

JULY-2015

Department of Mechanical Engineering

Government Engineering College, Dahod

Jhalod Road, Dahod, Gujarat-389151

i
 THESIS APPROVAL CERTIFICATE

This is to certify that research work embodied in the thesis entitled

“INVESTIGATION OF CUTTING FORCE AND TOOL WEAR BEHAVIOR IN
DRY TURNING OF INCONEL 625” was carried out by Mr. VADALIA DEEP D.
(130180708005), studying at Government Engineering College, Dahod (018) is
approved for the award of degree of Master of Engineering in MECHANICAL (CAD-
CAM) by Gujarat Technological University.

Date:

Place:

Examiner(s):

________________ _______________ _______________

( ) ( ) ( )

ii
 CERTIFICATE

This is to certify that research work embodied in the thesis entitled

“INVESTIGATION OF CUTTING FORCE AND TOOL WEAR BEHAVIOR IN
DRY TURNING OF INCONEL 625” was carried out by Mr. VADALIA DEEP D.
(130180708005), studying at Government Engineering College, Dahod for partial
fulfillment of M.E. Degree to be awarded by Gujarat Technological University. This
research work has been carried out under my supervision and is to my satisfaction.

Date:

Place:

Prof. Alpesh Makwana Prof. R.I. Patel

Project Supervisor Head

Asst. Prof. Mechanical Engg. Dept. Mechanical Engg. Dept.

Government Engineering College, Dahod Government Engineering College, Dahod

Dr. U.K. Khare

Principal

Government Engineering College, Dahod

iii
 DECLARATION OF ORIGNALITY

I hereby certify that I am the sole author of the thesis and that neither any part
of this thesis nor the whole of the thesis has been submitted for a degree to any other
University or institution.

I certify that, to the best of my knowledge, the current thesis does not infringe
upon anyone‟s copyright nor violate any proprietary right and that any ideas,
techniques, quotations, or any other material from the work of other people included
in my thesis, published or otherwise, are fully acknowledged in accordance with the
standard referencing practices. Furthermore, to the extent that I have included
copyrighted material that surpasses the bounds of fair dealing within the meaning of
the Indian Copyright Act 2012, I certify that I have obtained a written permission
from the copyright owner(s) to include such material(s) in my thesis and have
included copies of such copyright of such copyright clearances to my appendix.

I declare that this is a true copy of thesis, including any final revisions, as
approved by thesis review committee.

I have checked write up of the present thesis using anti-plagiarism database

and it is in allowable limit. Even though later on in case of any complaint pertaining
of plagiarism, I am sole responsible for the same and I understand that as per UGC
norms, University can even revoke Master of Engineering conferred to the student
submitting the thesis.

Date:

Place:

Mr. Deep D. Vadalia

130180708005

iv
 COMPLIANCE CERTIFICATE

This is to certify that research work embodied in the thesis entitled

“INVESTIGATION OF CUTTING FORCE AND TOOL WEAR BEHAVIOR IN
DRY TURNING OF INCONEL 625” was carried out by Mr. VADALIA DEEP D.
(130180708005), studying at Government Engineering College, Dahod for partial
fulfillment of M.E. Degree to be awarded by Gujarat Technological University. He
has compiled to the comments given by the Dissertation phase – I as well as Mid
Semester Thesis Reviewer to my satisfaction.

Date:

Place:

Mr. Deep D. Vadalia Prof, Alpesh Makwana

M.E. Student (CAD/CAM) Asst. Prof. Mechanical Engg,. Dept.

Government Engineering College, Dahod Government Engineering College, Dahod

Dr. U.K. Khare

Principal

Government Engineering College, Dahod

v
 PAPER PUBLICATION CERTIFICATE

This is to certify that the research work emboided in this thesis entitled
“INVESTIGATION OF CUTTING FORCE AND TOOL WEAR BEHAVIOUR IN
DRY TURNING OF INCONEL 625” was carried out by Mr. DEEP D. VADALIA
(Enrollment No. 130180708005) at Government Engineering College, Dahod (018)
for partal fulfillment of Masters of Engineering degree to be awarded by Gujarat
Technological University, has presented article entitled “Investigation of cutting force
and tool wear behaviour in dry turning of Inconel 625” for publication by the
International Journal Of Advance Engineering And Research Development in Volume
2, Issue- 5 of May 2015.

Date:

Place:

Prof. Alpesh Makwana Prof. R.I. Patel

Project Supervisor Head

Asst. Prof. Mechanical Engg. Dept. Mechanical Engg. Dept.

Government Engineering College, Dahod Government Engineering College, Dahod

Dr. U.K. Khare

Principal

Government Engineering College, Dahod

vi
vii
viii
 ACKNOWLEDGEMENT

First and foremost, I express sincere thanks to my creative guide Prof. Alpesh
Makwana Assistant Professor in Mechanical Engineering Department, Government
Engineering College, Dahod, Gujarat Technological University for his valuable
guidance, motivation, cooperation, constant encouragement with ideas and healthy
criticisms that has made this dissertation possible. He showed faith in my work with
easy understanding and it has been a great pleasure to have him as my dissertation
mentor. I would like to thank Prof. R. I. Patel, Associate Professor and Head of the
Mechanical Engineering Department for supporting me to carry out this dissertation
work as a part of the curriculum. Without his motivation and search light at every
moment during entire dissertation, the dissertation would not have appeared in present
shape.

I heartily acknowledge to Prof. J. A. Bosco (M.E.), Senior Lecturer, CIPET,

Ahmadabad and Asst. Prof Kunal sir for providing me insightful direction, which
helped me explore the area of my dissertation. I heartily thankful to Shailesh
Kapadiya sir, IGTR, Ahmadabad, for his valuable guidance and vast knowledge about
Lathe machine, which will help me to carry out my experimental work. I wish to
thank all the faculty members of Mechanical Engineering Department and all the
people who have been part of the Government Engineering College, Dahod, for their
cooperation, guidance and support during the work.

I further would like to whole-heartedly express my gratitude to all my

colleagues, my parents for providing me their untiring support in the compilation of
this work.

DEEP D. VADALIA

(130180708005) M.E. 4th Semester

Mechanical Engineering Dept. (CAD/CAM)

ix
 TABLE OF CONTENTS

THESIS APPROVAL CERTIFICATE………………………………………………. ii

CERTIFICATE……………………………………………………………………… iii

DECLARATION OF ORIGNALITY…………………………………..…………… iv

COMPLIANCE CERTIFICATE……………………………………………….…….. v

PAPER PUBLICATION CERTIFICATE……………………………………...…… vi

INDUSTRIAL CERTIFICATE…………………………………………………….. vii

ACKNOWLEDGEMENT……………………………………………………….…...ix

TABLE OF CONTENTS……………………………………………………….…..…x

LIST OF FIGURES…………………………………………………………….……xiv

LIST OF TABLES……………………………………………………………….....xvii

ABSTRACT………………………………………………………………………....xix

CHAPTER 1 INTRODUCTION…………………………………….………………...1

1.1 Overview…………………………………………………………………..1

1.2 About Inconel 625………………………………………………………....2

1.2.1 Heat Resistant Super Alloys……………………………………..2

1.2.2 Alloy Inconel 625……………………………………………..…3

1.2.3 Applications……………………………………………………...4

1.2.4 Properties………………………………………………………...5

1.3 Cutting Force……………………………………………………………....6

1.3.1 Introduction…………………………………………………..….6

1.3.2 Cutting Force Components…….………………………………...7

x
 1.3.3 Force determination……………………………………………...8

1.3.4 Cutting force control…………….………………………………8

1.4 Tool Wear……………………………………………………………….....9

1.4.1 Introduction………………………………………………….…..9

1.4.2 Failure modes of tool wear in brief……………………………...9

1.4.3 Flank wear and tool life………………………………………...13

1.5 Problem definition………………………………………………………..15

1.6 Objective…………………………………………………………………15

1.7 Summary…………………………………………………………………16

CHAPTER 2 LITERATURE SURVEY……………………………………………..17

2.1 Introduction………………………………………………………………17

2.2 Review about Inconel 625………………………………………………..17

2.3 Influence of machining parameters and coating on Cutting force on

Tool………………………………………………………………….…….…17

2.4 Influence of cutting parameters and coating on flank wear……………...20

2.5 Dry turning……………………………………………………………….24

2.6 Summary…………………………………………………………………27

CHAPTER 3 DESIGN OF EXPERIMENTS………………………………………..28

3.1 Introduction to design of experiments……………...…………………….28

3.1 Central Composite Design………………………………….…………….28

3.2 Design of Experiments…………………………………………………...30

3.3 Summary…………………………………………………………………33

CHAPTER 4 EXPERIMENTAL ANALYSIS………………………………………34

xi
 4.1 Experimental Setup………………………………………………………34

4.2 Machine Tool (Turning Center Lathe)…………………………………...35

4.2.1 Work Specimen………………………………………………...35

4.2.2 Cutting tool Geometry………………………………………….36

4.2.3 Cutting Insert geometry………………………………………...36

4.3 Lathe Tool dynamometer………………………………………………...38

4.3.1 IEICOS Lathe Tool Dynamometer – Model 621C: 500

KgF.......................................................................................................38

4.3.2 IEICOS Multi component Digital Force Indicator 3 Channel

Model 652……….……………………………………...………….…40

4.4 Operating Instructions……………………………………………………41

4.5 Tool makers Microscope…………………………………………………42

4.6 Industries/Institute visited…………………………….………………….44

4.7 Summary…………………………………………………………………44

CHAPTER 5 RESULTS AND DISCUSSIONS……………………………………..45

5.1 Experimental Results……………………………………………….…….45

5.2 For Iscar Insert…………………..….…………………………………….46

5.2.1 ANNOVA and regression…..………………….………………46

5.2.2 Residual Plots…………………………………………………..53

5.2.3 Contour plots and 3-D surface plots……………………………55

5.2.4 Optimum settings………………………………………………58

5.3 For Korloy Insert…………………………………………………………59

5.2.1 ANNOVA and regression…..………………….………………59

xii
 5.2.2 Residual Plots…………………………………………………..66

5.2.3 Contour plots and 3-D surface plots……………………………68

5.2.4 Optimum settings………………………………………………71

5.4 Comparison of flank wear………………………………………………..72

5.5 Cutting force graphical representation…………………………………...73

5.5.1 Iscar insert……………………………………………………...73

5.5.2 Korloy insert……………………………………………………73

5.6 Summary…………………………………………………………………73

CHAPTER 6 CONCLUSION………………………………………………………..74

FUTURE SCOPE…………………………………………………………………….76

REFRENCE…………………………………………………………………………..77

NOMENCLATURE………………………………………………………………….79

APPENDIX………………………………………………………………………..…80

Appendix 1: Symbols………………………………………………………...81

Appendix 2: Research paper presented/published……………………………81

xiii
 LIST OF FIGURE

Fig. 1.3.1: Cutting force reaction…………………………………………………….06

Fig. 1.3.2: Cutting force components………………………………………………...07

Fig. 1.4.2: Tool failure modes due to wear [8 figures]…………………….…………09

1. Flank wear………………………………………………………..…………..09
2. Cratering……………………………………….…………………….……….10
3. Built up Edge………………………………….………………………….…..10
4. Chipping……………………………………………….……………………..11
5. Thermal mechanical failure…………………....…………………….….........11
6. Edge deformation……………………………….…………………………....12
7. Notching………………………………………….…………………………..12
8. Mechanical Fracture………………………………………….…....................13

Fig. 1.4.3 (a): Types of wear observed in cutting tools……………………...……….13

Fig. 1.4.3 (b): Flank wear as a function of cutting time……………………………...14

Fig. 1.4.3 (c): Cutting tool wear as a function of basic process parameters………….15

Fig. 3.1: Central composite designs for two factors and three factor…………..……28

Fig. 3.2: Design of Experiment in MINITAB®17…………………………………..30

1. Create Response Surface Design……………………………………………..31

2. Select CCD Design……………………………………………………….......32
3. Select appropriate design……………………………………………………..32
4. Define factors………………………………………………………………...33
5. Get D.O.E as a output……………………………………………………...…33

Fig. 4.1: Experimental setup….………………………………………………………34

Fig. 4.2: Conventional lathe machine………………………………………………...35

Fig. 4.2.2: Cutting tool ………………………………………………...…………….36

Fig. 4.2.3(a): Cutting tool bit…………………………………………………………36

xiv
Fig. 4.2.3(b): Cutting tool bit geometry……………………………………………...37

Fig. 4.3.1(a): Lathe tool dynamometer……………………………………………….38

Fig. 4.3.1(b): Dynamometer cable attachment……………………………………….39

Fig. 4.3.2(c): Multi component digital force indicator……………………………….40

Fig. 4.3.3(a): Tool attachment with dynamometer……………………………….......41

Fig. 4.3.3(b): Dynamometer attachment with lathe…………………………………..41

Fig. 4.4: Tool maker‟s microscope……………………………………………...……43

Fig. 5.1: Work piece after experiment………………………………………………..46

Fig. 5.2.1(a): Main effect plot for feed force (Fx)……………………………………48

Fig. 5.2.1(b): Interaction plot for feed force (Fx)…………………………………….49

Fig. 5.2.1(c): Main effect plot for main cutting force (Fy)…………………………..50

Fig. 5.2.1(d): Interaction plot for main cutting force (Fy)…………………………...50

Fig. 5.2.1(e): Main effect plot for flank wear (Vb)…………………………………..50

Fig. 5.2.1(f): Interaction plot for flank wear (Vb)……………………………………51

Fig. 5.2.2(a): Residual plots for feed force (Fx)……………………………..……….53

Fig. 5.2.2(b): Residual plots for main cutting force (Fy)…………………….………53

Fig. 5.2.2(c): Residual plots for Flank wear (Vb)……………………………………54

Fig. 5.2.3(a): Contour plot of feed force (Fx)………………………………………..55

Fig. 5.2.3(b): 3-D surface plot for feed force (Fx)…………………………………...55

Fig. 5.2.3(c): Contour plot for main cutting force (Fy)...............................................56

Fig. 5.2.3(d): 3-D surface plot for main cutting force (Fy)…..………………………56

Fig. 5.2.3(e): Contour plot for feed force (Vb)………………………………………57

Fig. 5.2.3(f): 3-D plot for feed force (Vb)……………………………………………57

xv
Fig. 5.3.4: Optimization plot for Iscar insert……………………………………...….58

Fig. 5.3.1(a): Main effect plot for feed force (Fx)………………………………...….61

Fig. 5.3.1(b): Interaction plot for feed force (Fx)…………………………………….62

Fig. 5.3.1(c): Main effect plot for main cutting force (Fy)…………………………..62

Fig. 5.3.1(d): Interaction plot for main cutting force (Fy)…………………………...63

Fig. 5.3.1(e): Main effect plot for flank wear (Vb)…………………………………..63

Fig. 5.3.1(f): Interaction plot for flank wear (Vb)……………………………………64

Fig. 5.3.2(a): Residual plots for feed force (Fx)……………………………………...66

Fig. 5.3.2(b): Residual plots for main cutting force (Fy)…………………………….66

Fig. 5.3.2(c): Residual plots for Flank wear (Vb)……………………………………67

Fig. 5.3.3(a): Contour plot of feed force (Fx)………………………………………..68

Fig. 5.3.3(b): 3-D surface plot for feed force (Fx)…………………………………...68

Fig. 5.3.3(c): Contour plot for main cutting force (Fy)………………………………69

Fig. 5.3.3(d): 3-D surface plot for main cutting force (Fy)…………………………..69

Fig. 5.3.3(e): Contour plot for feed force (Vb)………………………………………70

Fig. 5.3.3(f): 3-D plot for feed force (Vb)……………………………………………70

Fig. 5.3.4: Optimization plot for Korloy Insert………………...…………………….71

Fig. 5.4: Comparison of flank wear…………………………..………………………72

Fig 5.5.1: Cutting force representation-Iscar and Korloy insert……………..……….73

xvi
 LIST OF TABLES

Table 1.2.1: Aerospace and gas turbine Nickel Base………………………………...02

Table 1.2.2: Nominal chemical composition (% weight)…………………………….03

Table 1.2.3: Applications of Inconel 625…………………………………………....04

Table 1.2.4(a): Physical properties…………………………………………...............05

Table 1.2.4(b): Describe the features of HRSA material and the corresponding tool
properties required for that...…………………………………………………………05

Table 2.1: Overview of Literature work……………………………………………...25

Table 3.1: Depict the CCD for a two process parametric application………………..32

Table 3.2: Design of Experiments…………………………………………………....33

Table 4.2.1: Work specimen details………………………………………………….35

Table 4.2.2: Cutting tool geometry...………………………………………………...37

Table: 4.2.3(a): Cutting tool bit………………………………………………………38

Table 4.3.1: Specification of lathe tool dynamometer…………………………….....39

Table: 4.3.2: Specification Multi component force indicator……………………......40

Table: 4.4: Tool makers microscope………………………………………………....43

Table 5.1: Experimental Data……………………………………………….………..45

Table 5.2.1 (a): ANNOVA for Feed Force (Fx)……………………………..……….46

Table: 5.2.1(b): ANNOVA for main cutting force (Fy)……………………………...46

Table: 5.2.1(c): ANNOVA for main flank wears (Vb)………………...…….………47

Table 5.2.1(d): Estimated Coded Regression Coefficients for Feed Force (Fx)….….51

Table 5.2.1(f): Estimated Coded Regression Coefficients for Main cutting Force (Fy)
………………………………………………………………………………………..52

xvii
Table 5.2.1(g): Estimated Coded Regression Coefficients for Flank wear (Vb)…….52

Table 5.3.1 (a): ANNOVA for Feed Force (Fx)…………………………………..…59

Table 5.3.1(b): ANNOVA for main cutting force (Fy)……………………………....59

Table 5.3.1(c): ANNOVA for main flank wears (Vb)……………………………….59

Table 5.3.1(d): Estimated Coded Regression Coefficients for Feed Force (Fx)……..64

Table: 5.3.1(e): Estimated Coded Regression Coefficients for Main cutting Force (Fy)
………………………………………………………………………………………..65

Table: 5.3.1(f): Estimated Coded Regression Coefficients for Flank wear (Vb)…….65

xviii
 INVESTIGATION OF CUTTING FORCE AND
TOOL WEAR BEHAVIOUR IN DRY MACHINING
OF INCONEL 625

Submitted By

DEEP D. VADALIA

ENROLLMENT NO.: 130180708005

Supervised by

Prof. ALPESH MAKWANA

Assistant Professor

Mechanical Engineering Department

Government Engineering College, Dahod-389151

ABSTRACT

This thesis presents the performance of cutting tool while dry turning Inconel
625 a Nickel based super alloy, one of the most difficult to machine materials. One
such alloy belonging to Nickel based family which has been extensively used by
researchers is Inconel 718.

Recently Inconel 625 with high level of strength without heat treatment, good
corrosion and acid resistance properties than Inconel 718 is of little attention to
researchers. These properties have led Inconel 625 in diverse applications like
aerospace, automobile, chemical processing, ultra critical steam piping and many
others.

The cooling lubricant during machining is of prime importance but the cost
associated with its use cannot be neglected. To reduce the cost associated and make

xix
the process environmentally safe, the goal of the manufacturers is to move towards
dry machining in near future. To achieve this different coated tools and different
cutting conditions are tested.

The present work investigates the Main Cutting force and feed cutting forces
in orthogonal cutting process. The variation of the average flank wear and the wear
behavior of the cutting tool with the change in the machining parameter are identified.
Design of experiment was done using full factorial Central Composite Design. Lathe
tool dynamometer and Tool maker‟s microscope was used to measure force acting on
tool and flank wear respectively. The data was compiled into MINITAB®17 for
analysis. The relation between the machining parameters and the response variable
were modeled and analyzed using Response Surface Methodology (RSM). Analysis
of Variance (ANNOVA) was used to determine the significance of these parameters
on response variables with the machining parameters as the independent variables,
with the help of quadratic model. Main effect and Interaction plots were obtained and
studied along with the contour ad 3-D surface plots.

Keywords: Inconel 625, Dry turning, CCD, RSM, Cutting force, Flank wear

xx
 CHAPTER 1

INTRODUCTION

1.1 Overview

The widely used metal cutting operation in industries is turning operation [3].
High performance can be accomplished by selecting the machining parameters
properly. By high performance, we mean we achieve good machineability, better
surface finish, lesser rate of tool wear, higher material removal rate, faster rate of
production etc.

Tool wear is an inherent phenomenon in every traditional cutting operation.

Researchers try to elimination or minimization of tool wear as tool wear affects
[4]
product quality as well as production costs. For improving tool life, extensive
studies on the tool wear characteristics have to be conducted Some of the factors that
affect tool wear are machining parameters like cutting speed, feed, depth of cut etc.,
tool material and its properties, Work material and its properties and tool geometry.
Small changes in the above mentioned factors may bring about significant changes in
the product quality and tool life

In order to achieve desired results, optimization is needed [5]. Optimization is

the science in which we get most excellent results subjected to several resource
constraints. Statistical design of experiments is used quite extensively in optimization
processes. Statistical design of experiments is the process of planning the experiments
so that appropriate data can be analyzed by statistical methods, resulting in valid and
objective conclusions Methods of design such as Response Surface Methodology
(RSM), Taguchi‟s method, factorial designs etc., and find unbound use nowadays
replacing the erstwhile one factor at a time experimental approach which more costly
as well as time-consuming.

In this thesis machining of Inconel 625 was carried out by two different coated
PVD tools and their performance was evaluated by measuring the response with
different cutting parameters. The cutting performance of two different coated inserts
was evaluated.

1
1.2 About Inconel 625

It is important to study the properties of the work piece material to be

machined as it plays the major role in knowing the characteristics of the responses
acing on the cutting tool while machining.

1.2.1 Heat resistant super alloys

[2]
A super alloy is an alloy that exhibits excellent mechanical strength and
resistance to creep (tendency for solids to slowly move or deform under stress) at high
temperatures; good surface stability; and corrosion and oxidation resistance. HRSA
represent the largest group of materials in current aero engine manufacturing.

Heat resistant super alloys (HRSA) can be divided into four material groups

1. nickel-based
2. cobalt-based
3. iron-based
4. titanium alloys

The physical properties and machining behavior of each varies considerably,

due both to the chemical nature of the alloy and the precise metallurgical processing it
receives during manufacture. Whether the metal is annealed or aged is particularly
influential on the subsequent machining properties

Table 1.2.1: Aerospace and Gas Turbine Nickel Base

IMAGE COMPONENT Turning Drilling Milling Others

Disc 60% 10% 5% 25%

Casing 45% 40% 15%

2
 Ring 95% 5%

Blade 10% 50% 40%

Shaft 70% 5% 25%

1.2.2 Alloy Inconel 625

[1]
Alloy 625 is an austenitic nickel-chromium-molybdenum-niobium alloy
which possesses a rare combination of outstanding corrosion resistance coupled with
high strength from cryogenic temperatures to 982°C.The strength of Alloy 625 is due
to the solid-solution hardening of the nickel-chromium matrix by the presence of
molybdenum and niobium.

[1]
Table 1.2.2: Nominal chemical composition (% Weight)

Nickel 58 min

Chromium 20.0-23.0

Iron 05 max

Molybdenum 08.0-10.0

Niobium 3.15-4.15

Carbon 0.10 max

Manganese 0.50 max

Silicon 0.50 max

3
Phosphorus 0.015 max

Sulphur 0.015 max

Aluminium 0.40 max

Titanium 0.40 max

Cobalt max

The chemical composition of Alloy 625 is also making it a outstanding

corrosion resistance material in a variety of severe operating environments along with
resistance to oxidation and carburization in high temperature service. The alloy is
resistant to pitting, crevice corrosion, impingement corrosion, inter-granular attack
and is almost immune to chloride stress corrosion cracking. Alloy 625 can also be
easily welded and processed by standard shop fabrication practices.

1.2.3 Application of Inconel 625

[3]
Table 1.2.3: Applications of Inconel 625

bellows and expansion joints, ducting

Aerospace Component
Air Pollution Control
Chemical processing
Marine Service
Nuclear Industry
systems, jet engine exhaust systems,
engine thrust-reversers, turbine shroud
rings
chimney liners, dampers, flue gas
desulfurization (FGD) components
equipment handling both oxidizing and
reducing acids, super-phosphoric acid
production
steam line bellows, Navy ship exhaust
systems, submarine auxiliary propulsion
systems
core and control rod components, waste
reprocessing equipment

4
1.2.4 Properties of Inconel 625

[1]
Table 1.2.4(a): Physical properties

Yield Strength Ultimate Tensile Elongation in 2

Hardness
(MPA) Strength (MPA) in. %
200 brinel NO.
448 862 50
(75 HRb)

Density 8.44 gm/cm3

Modulus of elasticity 207.5 GPA
Melting range 1290-1350 ºC
Specific Heat 427 J/Kg-ºC (0-100ºC)
Thermal Conductivity 10.8 W/m-ºC
Electrical Resistivity 128.9 Micro ohm-cm at 21ºC

[2]
Table 1.2.4(b): Describes the features of HRSA material and the corresponding
tool properties required for that

Feature of HRSA Demand on cutting Tool

Strength is retained at high temperature High cutting force
High dynamic shear strength High cutting force
Poor thermal conductivity High temperature generated
Hard enable to 46 HRC High temperature generated
Surface prone to work hardening High Notching tendency
Hard carbides in structure Abrasive

Machining: Alloy 625 should be machined in the annealed condition. Since

Alloy 625 is prone to work-hardening it should be only machined at low cutting
speeds. Adequate depth of cut is necessary to assure avoiding contact with the
previously formed work-hardened zone.

Oxidation Resistance: The oxidation and scaling resistance of Alloy 625 is

superior as compared to heat resistant austenitic stainless steels such as 304, 309, 310

5
and 347 up to 1800°F (982°C) and under cyclic heating and cooling conditions.
Above 1800°F (982°C), scaling can become a restrictive factor in service.

Corrosion Resistance: The highly alloyed chemical composition of Alloy 625

imparts outstanding corrosion resistance in a variety of severely corrosive
environments. The alloy is virtually immune to attack in mild conditions such as the
atmosphere, fresh and sea water, neutral salts and alkaline solutions. Nickel and
chromium provide resistance to oxidizing solutions and the combination of nickel and
molybdenum supply resistance in non-oxidizing environments. Molybdenum also
makes Alloy 625 resistant to pitting and crevice corrosion, while niobium acts as a
stabilizer during welding to prevent inter granular cracking. The high nickel content
of Alloy 625 makes it virtually immune to chloride stress corrosion cracking. The
alloy resists attack by mineral acids such as hydrochloric, nitric, phosphoric and
sulfuric, and to alkalis and organic acids in both oxidizing and reducing conditions.

1.3 Cutting Force

1.3.1 Introduction

Metal Cutting is a process where extensive stresses and plastic deformations

occur. The high compressive and frictional contact stresses on the tool face result in
substantial cutting force acting on the tool.

Fig. 1.3.1: Cutting force reaction

6
Learning about cutting forces is essential for the following reasons:

 designing proper cutting tools

 design of the fixtures used to hold the work piece and cutting tool
 calculating the machine tool power
 selecting the cutting conditions to avoid an large distortion of work piece

1.3.2 Cutting force components

In orthogonal cutting, the total cutting force F is resolved into two components
in the horizontal and vertical direction, which can be directly measured using a force
measuring device called a dynamometer. If the force and its components are plotted at
the tool point instead of at their actual points of application along the shear plane and
tool face, we obtain a convenient and compact diagram. The two force components
act against the tool:

Cutting force FC: This force is in the direction of primary motion. The cutting
force constitutes about 70~80 % of the total force F and is used to calculate the power
P required to perform the machining operation. Thrust force FD is in direction of feed
motion in orthogonal cutting. The thrust force can be used to calculate the power of
feed motion. In three-dimensional oblique cutting, one more force component appears
along the third axis. The thrust force FD is further resolved into two more components,
one in the direction of feed motion called feed force Ff, and the other perpendicular to
it and to the cutting force FC called back force FP, which is in the direction of the
cutting tool axis.

Fig 1.4.2: Cutting force components

7
1.3.3 Force determination

Cutting forces are either

 measured in the real machining process, or

 Predicted in the machining process design.

Cutting forces are measured by means of special device called tool force
dynamometer mounted on the machine tool.

1.3.4 Cutting force control

The cutting force value is primarily affected by:

 cutting conditions (cutting speed V, feed f, depth of cut d)

 cutting tool geometry (tool orthogonal rake angle)
 properties of work material

The easiest way to control cutting forces is to change the cutting conditions.
The next diagrams show the dependencies between FC and cutting conditions:

The cutting speed V does not affect significantly the cutting force FC.
Increasing the cutting speed slightly reduces the cutting force slightly. The
dependence is more complex in the low speed range for materials, which tend to form
a built-up edge. When the built-up edge disappears at high cutting speeds, the
dependence is essentially the same as this for materials, which do not form a built-up
edge at all. Feed changes significantly the cutting force. The dependence is non-linear
because of the so-called size effect at low feeds. Depth of cut also changes
significantly the cutting force but the dependence now is linear.

It can be concluded that the most effective to control force is to change the
depth of cut and feed rate. Machining with positive tool orthogonal rake angles will
decrease significantly the cutting force but at the same time will increase the
possibility of tool breakage.

8
1.4 Tool wear

1.4.1 Introduction

Wear occurs as a natural consequence when two surfaces with a relative motion
interact with each other. Wear may be defined as the progressive loss of material from
contacting surfaces in relative motion. A useful definition for a worn out tool is: “A
tool is considered to be worn out when the replacement cost is less than the cost for
not replacing the tool”. Tool is said to have failed when the tool no longer performs
the desired function whereas ultimate failure is defined as the complete removal of the
cutting edge, a condition obtaining when catastrophic failure occurs. In machining
operations, tools are considered to be worn out and are changed earlier before total
failures occurs to avoid incurring high costs associated with such catastrophic failures.
The tool also experience repeated impact loads during interrupted cuts, and the work
piece chips may chemically interact with the tool materials. The useful life of a
cutting tool may be limited due to variety of wear processes like crater wear, flank
wear or abrasive wear, built up edge, notching and nose wear.

1.4.2 [22] Failure modes of tool due to wear in brief

1. Flank Wear

Cause: Abrasive wear. Hard microscopic particles or work-hardened material

in the work piece cut into the insert, wearing away the cutting edge.

[1]

 Relatively uniform abrasion along the cutting edge

 Occasionally, metal from the work piece that is smeared over the cutting edge
can exaggerate the apparent size of the wear scar.

9
2. Cratering

Cause: A combination of diffusion, decomposition and abrasive wear causes

cratering. The heat from work piece chips promotes decomposition of the tungsten
carbide grains in the cutting tool, wearing a „crater‟ on the top of the insert. The crater
will eventually grow large enough to cause the insert flank to chip or deform.

[2]

 Craters or pits on top of inserts

 Chip breaking may improve after cratering starts

3. Built Up Edge

Cause: Material adhesion BUE is a result of the work piece material being
pressure welded to the cutting edge. This occurs when there is chemical affinity, high
pressure, and sufficient temperature in the cutting zone. Eventually, the built up edge
breaks off and often takes a piece of the cutting edge with it, leading to chippage and
rapid flank wear.

[3]

 Shiny material on the top or flank of the insert edge

 Erratic changes in part size or finish

10
4. Chipping

Cause: Mechanical instability chipping of the insert edge is often a result of

vibrations in the work piece or spindle. Hard inclusions in the surface of the material
being cut and Interrupted cuts result in local stress concentrations that can cause
chipping.

[4]

 Chips along the edge of the insert

5. Thermal Mechanical Failure

Cause: A combination of thermal cycling (changing the temperature of the

insert very rapidly), thermal load (temperature differences between warm and cold
zones), and mechanical shock causes thermal mechanical failure. Stress cracks form
along the insert edge, eventually causing sections of carbide to pull out and appear to
be chipping. This is the most common failure mode encountered in milling
applications.

[5]

 Multiple cracks perpendicular to cutting edge

 Need to identify before chipping occurs

11
6. Edge Deformation

Cause: Excessive heat. Excessive heat causes the carbide binder (cobalt) to
soften. Mechanical Overloading Pressure of the insert against the work piece makes
the insert deform or sag at the tip, eventually breaking off or leading to rapid flank
wear.

[6]

 Deformation at the cutting edge

 The dimensions of the work piece may not be as expected

7. Notching

Cause: Hard or abrasive surfaces on the work piece. Notching is caused when
the surface of the work piece is harder or more abrasive than the material deeper in
the cut, e.g. surface hardening from previous cuts, forged or cast surfaces, or surface
scale. This causes the insert to wear more rapidly at the depth of cut line. Local Stress
Concentration can also lead to notching. As a result of the compressive stress along
the cutting edge – and lack of the same behind the cutting edge – the insert is
particularly stressed at the depth of cut line.

[7]

 Notching or chipping at the depth of cut area on the insert

12
8. Mechanical Fracture

Cause: Mechanical overload. The mechanical load is so great that the insert
breaks, often during the first moments of a cut. Excessive wear of any type can cause
mechanical fracture.

[8]

 Fracture of insert. Large segments of the insert gone.

1.4.3 Flank wear and tool life

Flank wear occurs on the tool flank as a result of friction between the
machined surface of the work piece and the tool flank. Flank wear appears in the form
of so-called wear land and is measured by the width of this wear land, VB, Flank wear
affects to the great extend the mechanics of cutting. Cutting forces increase
significantly with flank wear. If the amount of flank wear exceeds some critical value
(VB > 0.5~0.6 mm) the excessive cutting force may cause tool failure.

Fig. 1.4.3(a): Types of wear observed in cutting tools

13
Tool Life

Tool wear is a process which is dependent on time. As cutting time proceeds,

the amount of tool wear also increases gradually. But tool wear must not be allowed
to go beyond a certain limit in order to avoid tool failure. Among all the wear types
the most important wear type from the process point of view is the flank wear;
therefore the parameter which has to be controlled is the width of flank wear land, VB.
This parameter must not exceed an initially set safe limit, which is about 0.4 mm for
carbide cutting tools. The safe limit is referred to as allowable wear land (wear
criterion), VBk. The cutting time required for the cutting tool to develop a flank wear
land of width VBk is called tool life, T, a fundamental parameter in machining. The
general relationship of VB versus cutting time is shown in the figure is called wear
curve. Although the wear curve shown is for flank wear, a similar relationship occurs
for other wear types. The figure shows also how to define the tool life T for a given
wear criterion VBk.

Fig. 1.4.3 (b): Flank wear as a function of the cutting time

Tool life T is defined as the cutting time required for flank wear to reach the value of
VBk Parameters, which affect the rate of tool wear

 cutting conditions (cutting speed V, feed f, depth of cut d)

 cutting tool geometry (tool orthogonal rake angle)
 properties of work material used

The tool life values for the wear curves are plotted on a natural log-log graph
of cutting speed versus tool life as shown in the right figure, the resulting relationship
is a straight line expressed in equation form called the Taylor tool life equation:

VTn = C

14
 Where n and C are constants, whose values depend on the cutting conditions,
work and tool material Properties and tool geometry.

Fig. 1.4.3[c]: Cutting tool wear as a function of basic process parameters

1.5 Problem Definition

During machining of Inconel 625 the machinist faces several problems due to
its strength, low thermal conductivity, abrasiveness, and tendency to work harden.
Work hardening occurs whenever a tool makes a cut. The machined surface of the
component is deformed slightly during the cut, leaving it substantially harder than the
original material. This results in notching and chipping during subsequent machining
passes. Also abrasive wear occurs due to hard microscopic particles or work-hardened
material in the work piece cut into the insert, wearing away the cutting edge.

1.6 Objective

To overcome these problems industries have started using sharper, more

positive cutting edges, typically PVD (physical vapor deposition) coated tools, reduce
this phenomenon, and are therefore preferred. An additional complication, related to
the toughness of this alloy, is that chips are difficult to break. All of these factors
dictate that a correct combination of tool, tool geometry and cutting data is essential
for good machining results. So two different coated inserts were used to machine

15
Inconel 625 by varying the cutting parameters to measure the cutting force and wear
acting on the tool and their optimal performance were evaluated.

This thesis presents the use of coated tool for dry turning of Inconel 625 and
investigating the cutting force acting and the tool wear behavior for different
machining parameters. Two different coated insert of same geometry were used to
machine Inconel 625 and their cutting performance was evaluated.

1.7 Summary

This chapter presents the basic idea about the importance of selection of
different machining parameters during machining process and their effect on the
machinability. Importance of optimization techniques is highlighted. The problems
during machining of Inconel 625 and the ways to overcome them are discussed.

16
 CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

The ensuing chapter covers published work of researchers pertaining to the

turning process in order to optimize parameters. Specifically, theory and information
relating to the experiment and the turning process is presented. The scope of the
review also extends to various optimization techniques that are used to obtain optimal
solution mainly focusing on the Response Surface Method.

2.2 Reviews about Inconel 625

[7]
G.D. Smith, D.J. Tillak and S.J. Patel reviewed the markets where alloy
INCONEL 625 is the material of the choice and explains the reason over its success.
Its ability to resist low temperature aggressive corrosion resistance environments as
well as hostile high temperature environments with a high level of strength has
enabled to specify it in diverse cross section of industries. INCONEL 625 has been
widely used in steam line piping, aerospace, automobile, chemical processing, oil
production, oil refining, marine, waste treatment and power industries. It was also
seen that a slight modification in the composition can lead to increase in fatigue life of
the alloy. INCONEL 625 also found its specification as filler materials for dissimilar
welding.

2.3 Influence of machining parameters and coating on Cutting

force on tool
[8]
A.Devillez, F. Schneider, S. Dominiak, D. Dudzinski, D. Larrouquere
found out the cutting force and wear in dry turning of Inconel 718 with using coated
carbide tools. Uncoated insert and coated insert with coatings like AlTiN, TiAlN,
TiAlN+Wc/C, TiAlN+MoST (MoS₃+Ti) were used. The first stage of tool wear was

17
investigated. The cutting forces were measured and the cutting force ratio calculated
as a significant factor of Tribological tool behavior. Cutting speed in the range of 20-
200m/min, feed 0.1-0.2m/min and depth of cut was 1.5 mm for all the tests. Spindle
consumed power is an interesting parameter that can be used to monitor tool wear.
The main wear modes observed during dry cutting Inconel 718 were welding and
adhesion of workpiece material onto the rake and flank faces. The work material
adheres to the cutting edge to form a BUE, and BUL on tool faces. Depending on
cutting conditions and on used tool, the BUE and BUL are not always stable and
sometimes fragments of adhering work material are removed, they can drag out tool
particles leading to a crater on rake face, a band of wear on flank face and to
important notching at the extremities of width of cut. Abrasion flank wear is also
possible, it was depicted during bar turning tests, and it may be produced by due to
hard carbide particles contained in this super alloy. In this work, it was shown that
the use of energy dispersive X-ray analysis and white light interferometer to observe
the wear mechanisms is very convenient.

In particular, white light interferometer analysis provides the surface

topography of the tool with the surface defaults corresponding to the different wears
modes such as adhesive wear, notching wear and coating delimitation. Energy
dispersive X-ray allows the composition analysis of the tool wear patterns,
particularly the characterization of the built-up-layers observed after dry machining
Inconel 718. It can be noted that the built-up-layer, if it is stable, has protective effect
on the tool, more precisely on cutting edge. A good correlation was observed between
the evolution of the cutting forces and the tool wear observations.

The occurrence of an important wear on the rake face of the tool has an
immediate effect in increasing the cutting force ratio. These results help us to
determine the optimal cutting conditions for dry machining of Inconel 718.The AlTiN
coating seems to be the best coating. Its good Tribological behavior limits welding
and unstable built-up-edge phenomena, abrasive wear is also reduced by its very high
hardness due to its ultra-fine crystalline. A bar turning test was finally performed with
the defined optimal cutting conditions to determine the time life of the AlTiN coated
tool. An interesting correlation was found between the tool wear and the consumed
spindle power.

18
 [9]
K. Venkatesan, R. Ramanujan, VimalSaxena, NilendukarChawdhury
and VikashChoudhry studied the influence of cutting parameters on dry machining
of Inconel 625 alloy with coated carbide inserts (PVD AlTiN). Taguchi L₉ orthogonal
array was used with turning experiments conducted at three levels of cutting speed
(30, 50, 70 m/min), feed (0.103, 0.206, 0.294 mm/rev) and depth of cut (0.2, 0.3,0.4
mm). For different cutting conditions cutting force and surface quality (surface
roughness) were investigated. Based on the analysis of response graph and
ANNOVA, cutting force was found to be the most significant parameter for surface
quality followed by feed and depth of cut was found to have no significant effect.
Feed rate and depth of cut were found to be significant parameter for cutting force
while cutting speed has insignificant effect. From the research the effectiveness of
PVD AlTiN coated carbide insert has been identified while dry turning of Inconel
625.

[10]
R.S. Pawade , Suhas S. Joshi , P.K. Brahmankar, M. Rahman
investigated the cutting force acting on the Inconel 718 at high velocity V=125-475
m/min. Results showed that radial and feed force are almost equal and the main
cutting force is two to three times the radial component. It was noted that specimens
showing larger cutting forces generated poor surface finish as well as extensive
surface damage.

[11]
S.K. Choudhury, K.K Kishore developed a reliable mathematical model
for on line monitoring of tool flank wear in a turning process by establishing relation
between the flank wear and the ratio of the feed and the cutting force. For this C45
work piece was turned using HSS tool. A total of 27 experiments were carried out
with three levels factorial design using factors cutting speed, feed, and depth of cut
with each having three levels. The effect of cutting speed, feed, and depth of cut,
work piece diameter, and force ratio were studied independently by using
mathematical model developed and experiments. Flank wear increased almost linearly
with Feed rate, depth of cut and diameter. It was found that force ratio seems to
monitor the flank wear reliably and cutting speed was found to be the most
dominating factor among all. Comparison of predicted values obtained from the
mathematical model and experimental values for the flank wear shows good
agreement.

19
 [5]
Force signals are highly sensitive carriers of information about the
machining process and, hence, they are the best alternative for monitoring tool wear
(flank wear height). Thus the ratio between the feed force and cutting force
components (Ff/Fc) has to be found to provide a practical method for the
quantification for tool wear. Comparison of experimental and predicted values shows
good agreement. It was seen that flank wear increased almost linearly with the feed
rate, depth of cut and diameter.

Tool performance can be derived from the below given figure by evaluating
the cutting force ratio versus the cutting speed. This ratio does not give the coefficient
of friction. Several phenomena like bonding\seizure, sliding, plastic deformation
occurs on the tool during machining. Thus Coefficient of friction is not an appropriate
concept for dealing when getting the relation between the ratio of the feed and cutting
force components. The increase of cutting force ratio occurring after a minimum
value is surely due to rapid tool wear.

Thus after getting some correlations between the cutting force ratio and the
wear mechanisms in the flank and the cutting faces as in, the ratio can be used to
reveal the wear level of the cutting inserts.

2.4 Influence of cutting parameters and coating on flank wear

[12]
Kejia Zhuang, Dahu Zhu, Xiaoming Zhang, Han Ding developed a
notch wear predictive model considering the influence of the work hardened layer in
which heat treated Inconel 718 round bar was turned with ceramic round type insert.
Total eight group of test were carried out with depth of cut as a variable which was
used to verify the geometric relations of cutting geometry and notch wear geometry.
In this paper a hypothesis based quantitative analysis of the relationship between
notch wear depth and the thickness of hardened layer was carried out. The main
failure modes of ceramic cutting tool during machining Inconel 718 are notch wear
and flank wear. It was found that the main cause of notch wear was due to hardened
layer beneath the work surface. They developed a new model having the relationship
between the notch wear depth and hardened layer depth. From the proposed model, no
notch wear occurred when hardened layer is limited and the increasing hardening

20
layer results in sharp increase in the notch wear depth. The proposed notch wear
model is based on the depth of hardening and the notch wear geometry.

[13]
A Thakur, A. Mohanty, S. Gangopadhyay, K.P. Maity investigated the
effect of tool wear and the corresponding chip characteristic. Inconel 825 bar of 75
mm diameter was turned with the help of uncoated and PVD multilayer coated
TiN/TiAlN) cemented carbide inserts (tool designation SNMG 12 04 08 SECO) in dry
environment. Uncut to cut chip thickness ratio was obtained for both uncoated and
coated tool at cutting speed of 51m/min and 84m/min at time duration of 30, 90,150
and 180 seconds with constant feed and depth of cut. It was observed that the chip
thickness ratio decreased with the machining duration which was due to the increase
in the wear. Chip curl radius increased with the progression of machining duration
when machined with uncoated inserts. Long and continuous chip were obtained
expect during machining durations of 30s and 180s. Chip thickness ratio increased
with the machining duration due to decrease in cutting speed. It was recommended to
use coated carbide inserts for machining Inconel 825 at high velocity for better tool
performance and productivity.

[14]
S.A. Khan, S.L. Soo, D.K. Aspinwall, P.Harden, M. Fleming, A.White,
R.M. Saoubi studied the tool wear when finish turning Inconel 718 using PCBN
Tool. Testing utilized a modified L₃₆ Taguchi factorial orthogonal array which
evaluated the effects of tool insert shape/geometry (round, C-type), tool edge
preparation (extra honed, chamfered and honed), fluid pressure (10,100 bar), tool
coating (uncoated, TiAlN+TiN), cutting speed (150,300,450 m/min) and feed rate
(0.05, 0.10, 0.20 mm/rev) at a constant depth of 0.2 mm. Flank wear was the most
dominant wear mode. In C-type of inserts, severe grooving and BUE was observed at
150 m/min while at highest cutting speed of 450 m/min insert fracture, chipping and
thermal cracks were observed.

ANNOVA calculations showed that cutting speed, feed and tool geometry had
a significant effect on tool life with corresponding percentage of 36.6%, 17.3% and
11.5%. Although not a statistically significant factor, the use of high pressure fluid
(100 bar) was occasionally detrimental to tool life particularly at low cutting speeds.

[15]
J.L. Cantero, J.Diaz Alvarez, M.H. Miguelez, N.C. Marin focuses on the
analysis of tool wear behavior in finish turning of Inconel 718 in dry and wet

21
conditions. Tool displacement direction was orthogonal to the lathe axis with constant
cutting speed. Two different carbide substrate CP500 and TS2000 were used with
coating of TiAlN and cutting edges E₁ and E₂ and kr as 0⁰ and 45⁰. It was proved
that substrate CP500, E₁, Kr 0⁰ was not proper for machining Inconel 718. Substrate
TS2000, E₁ Kr 0⁰ significant BUE, Chipping and notch wear were observed in all
tests. In substrate TS2000, E₂, Kr 0⁰ due to edge cutting angle E₂ edge resistance to
chipping was increased. In substrate TS2000, E₁, Kr 45⁰ the increment of Kr lead to
diminish undeformed chip thickness and in consequence pressure at the cutting edge.

It was studied that values of tool life are lower for dry conditions but they are
still reasonable while roughness increases slightly. Notch wear was seen due to the
high work hardening of the alloy. It was proved that tools with substrate TS2000, E₂,
Kr 0⁰ and TS2000, E₂, Kr 45⁰ were feasible for dry turning of Inconel 718. Strong
influence of cutting edge angle Kr has been observed in the wear evaluation

[16]
A.Altin, M.Nalbant, A.Taskeemstudied the effects of cutting speed in the
tool life and tool wear of Inconel 718. Silicon nitride based ceramic and whiskler
reinforced (Al₂O₃+SiCw). Alumina inserts were used. Generally flank wear, crater,
notching and plastic deformation are the wear mechanisms observed with ceramic
inserts. The dominant wear mechanisms seen at round type inserts are flank and notch
wear while flank and crater are the major wear types of square type of inserts. The
results showed that cutting speed above 250 m/min affects tool life negatively. Square
type inserts showed good performance compared to round type inserts at low cutting
speeds while at high cutting speed round type insert was recommended.

[17]
Dahu Zhu n, XiaomingZhang, HanDing Focused in tool wear
characteristics in machining of nickel based super alloys and fields of failure
mechanism, monitoring and prediction, and control of tool wear were reviewed. The
survey of existing works has revealed several gaps in the aspects of tool self-
organizing process based on the non-equilibrium thermodynamics, tool wear
considering the tool nose radius, thermal diffusion layer in coated tools, tool life
prediction based on the thermal–mechanical coupling, and industrial application of
tool wear online monitoring devices. The review aims at providing an insight into the
tool wear characteristics in the machining of nickel- based super alloys and shows the
great potential for further investigations and innovation in the field of tool wear.

22
 [18]
D. Dudzinski a,∗, A. Devillez a, A. Moufki a, D. Larrouque`re b, V.
Zerrouki b, J. Vigneau b found out that the main wear mechanism observed was
abrasion in cutting tools. Welding and Adhesion on the cutting tool frequently occur
to form a Built up edge. The BUE was repeatedly removed leading to extreme
notching. Machining induces plastic deformation and heat generation, the results are
metallurgical transformations and residual stresses on the machined surface layer. The
residual stress distribution exhibits a maximum tensile stress near the machined
surface and then a compressive stress. The depth of affected layer and the tensile and
compressive stresses increase when the cutting speed increases. Cemented carbide
tools are largely used for machining nickel-based alloys at very low cutting speeds of
20–30 m/min, the K20 grade appears to be the best for cutting Inconel 718. Higher
cutting speeds, certainly up to 100 m/min, under dry conditions may be achieved with
coated carbide tools. The PVD (TiAl)N coating seems to be most suitable. It displays
high oxidation resistance, high-temperature chemical stability, high hot hardness and
low thermal conduction. The monolayer structures with higher hardness appear to
give encouraging results much higher cutting speeds (from 200 to 700 m/min). The
Al2O3–TiC is the chemical most stable to Inconel 718; it has most thermal resistance
in high speed machining. Round inserts of SiC whisker-reinforced ceramic improve
the cutting performance for milling of Inconel 718, in comparison with the square
ones. Ceramics are poor conductors and vulnerable to thermal cracks and dry
machining is recommended with them. The use of coolants is undesirable for
environment and human health; furthermore, it induces high additional costs. New
concepts have been introduced to minimize coolant lubrication and in the same way
new coatings with a potential for dry machining have been developed. In dry
machining, the positive effects of coolants have to be obtained by another way. For
the removal of chips from cutting zone, heat evacuation must be guaranteed. The
process must preserve an acceptable surface integrity. Tools with high hot hardness,
high refractivity, low adhesion and low friction properties are required. Oxide PVD-
coatings combine a reduction of friction at elevated temperature with high wear
resistance; they show excellent performance during drilling high strength materials.
Solid lubricants such as MoS2/titanium composite coatings or WC/C coatings should
give useful results when machining Inconel 718 under dry conditions. Experiments
and machining simulation now have to work together to find a way to the dry cutting
of Inconel 718. The objective is to find the suitable tool and appropriate coating, to
23
define the better geometrical tool configuration and the optimal cutting conditions in
order to obtain more acceptable surface integrity and the longer tool life.

2.5 Dry turning

The economics of using cutting fluids have changed dramatically over the past
two decades. In the early ‟80s, buying, managing, and disposing of cutting fluids
accounted for less than 3 percent of the cost of most machining jobs. Today, fluids
including their management and disposal account for 16 percent of the cost of the
average job. Because cutting tools account for only about 4 percent of the total cost of
a machining project, accepting a slightly shorter tool life for the chance to eliminate
the cost and headaches of maintaining cutting fluids could be the less expensive
choice

And tool life may not even go down. Because coated carbide, ceramics,
cermets, cubic boron nitride (CBN), and polycrystalline diamond (PCD) are all brittle,
they are susceptible to the chipping and breaking caused by thermal stresses
especially those found in turning and milling operations that can be aggravated by the
introduction of coolant.Introducing a cutting fluid often makes the situation worse for
a simple reason. Most of the cooling effect goes to the parts of the work that are
already cooler than the cut. Experts debate whether any cutting fluid at all reaches the
cutting zone, the zone between the chip and the part, to control the heat of machining
at its source. Fluids tend to cool only the surrounding region areas that were
previously warm thereby intensifying temperature gradients and increasing thermal
stresses.

[19]
N. H. Rafia, and M. N. Islam, shows that for certain combinations of
cutting parameters, dry turning produced better dimensional accuracy compared to
that produced by flood turning. This indicates that, in the future, it will be possible,
through modelling the cooling process, to develop a system for finding in which
situations dry turning will be beneficial, thus reducing the application frequency of
cutting fluids and, consequently, their negative impact on the environment. The
results also show that no considerable difference in surface roughness is produced by

24
dry and flood turning. Some clear trends that appear in the traditional analyses are
difficult to explain. Therefore, further research is needed to investigate these trends.

[20]
P.S. Sreejith, B.K.A. Ngoi, paper presents recent developments in the dry
machining operation Machining without the use of any cutting fluid (dry or green
machining) is becoming increasingly more popular due to concern regarding the
safety of the environment. Most industries apply cutting fluids/coolants when their
use is not necessary. The coolants and lubricants used for machining represents 16-
20% of the manufacturing costs, hence the extravagant use of these fluids should be
restricted. However, it should also be noted that some of the benefits of cutting fluids
are not going to be available for dry machining and also dry machining will be
acceptable only whenever the part quality and machining times achieved in wet
machining are equaled or surpassed. Technology has to be further improved if dry
cutting is to be fully employed in industries.

Table 2.1: [7-20] Overview of literature work

METH PROBLE
Sr YE PAPER
AUTHOR SOURCE OD SUB M/
NO AR TITLE
TYPE SOLVING
Alloy 625 – Review the
Impressive markets of
G.D. Smith, Special
past/Significa Inconel 625
1 D.J. Tillak and 2000 Metal --
nt future/ and its
S.J. Patel Corporation
awesome success
future
Cutting force
A.Devillez, F.
and wear in WEAR Cutting
Schneider, S.
dry machining journal Force,
2 Dominiak, D. 2007 --
of Inconel 718 (science Wear
Dudzinski, D.
with coated direct) mechanism
Larrouquere
carbide tools
Influence of
cutting
K. Venkatesan, parameter
R. Ramanujan, in dry APN
Taguchi‟ Cutting
VimalSaxena, machining of Journals of
s DOE, Force,
3 NilendukarCha 2014 Inconel 625 engineering
ANNOV Surface
wdhury and alloy with and applied
A roughness
VikashChoudh coated science
ry carbide
insert –A
Statistical
25
Sr METH PROBLE
YE PAPER
N AUTHOR SOURCE OD SUB M/
AR TITLE
O TYPE SOLVING
Investigation
of cutting Cutting
force and Journal of Taguchi‟ Force,
R.S. Pawade , surface material s DOE, Surface
4 2007
Suhas S. Joshi damage in processing ANNOV Damage
high speed technology A (High
turning of speed)
Inconel 718
Tool wear
Internationa Flank Wear
measurement
S.K. l Journal of monitoring
in turning Taguchi‟
5 Choudhury, 2000 machine from
using force s DOE
K.K Kishore Tools and cutting
ratio
manufacture force ratio
Notch wear
prediction
model in
KejiaZhuang, turning of
WEAR
Dahu Zhu, Inconel 718 Model
journal
6 Xiaoming 2014 with ceramic -- predicting
(science
Zhang, Han tools notch wear
direct)
Ding considering
the influence
of the work
hardened layer
Tool wear and Flank wear,
A Thakur, A. chip chip
Procedia
Mohanty, S. Characteristics thickness
7 2014 Material --
Gangopadhyay, during dry ratio, chip
Science
K.P. Maity turning of morpholog
Inconel 825 y
Tool wear/life
S.A. Khan,
evaluation Procedia Wear
S.L. Soo, D.K.
when finish CIRP (5th Taguchi‟ mechanism
Aspinwall,
turning Conference s DOE, for
8 P.Harden, M. 2012
Inconel 718 on High ANNOV different
Fleming,
using PCBN Performanc A tool
A.White, R.M.
tooling e Cutting) geometry
Saoubi
Analysis of
tool wear
J.L. Cantero, Wear
pattern in WEAR
J.Diaz Alvarez, patterns
finish journal
9 M.H. 2013 -- (wet and
turning of (science
Miguelez, N.C. dry
Inconel 718 direct)
Marin turning)

26
Sr METH PROBLE
YE PAPER
N AUTHOR SOURCE OD SUB M/
AR TITLE
O TYPE SOLVING
The effect of
cutting speed
A.Altin, on tool wear
Materials Wear and
10 M.Nalbant, 2007 and tool life --
And Design tool life
A.Taskeem when
machining
Inconel 718
Review of
failure
mechanism
Tool wear Internationa
DahuZhu n, ,
characteristics l Journal of
XiaomingZhan monitoring
11 2013 in machining machine --
g, HanDing &
nickel based Tools and
prediction
super alloys manufacture
and control
of tool
wear
A review of
D. Dudzinski a,
development Internationa
A. Devillez a,
towards dry l Journal of
A. Moufki a, Wear
12 2004 and high machine --
D. Larrouquere mechanism
speed Tools and
b, V. Zerrouki
machining of manufacture
b, J. Vigneau b
Inconel 718
Comparison of
dry and flood Taguchi‟
N. H. Rafai, World
turning in s DOE, Surface
13 and M. N. 2010 Congress of
terms of ANNOV quality
Islam Engineering
quality of A
turned parts
Dry Journal of Dry
P.S. Sreejith*, machining : material machining :
14 2000 --
B.K.A. Ngoi, Machining Of processing environmen
future technology tal issues

2.6 Summary

The above research work represents the literature study done for research
which mainly includes the work done on super alloys. Literature on Inconel 625,
Cutting force and flank wear on tool, dry turning process and its importance has been
reviewed.

27
 CHAPTER 3

DESIGN OF EXPERIMENTS

3.1 Introduction to Design of Experiment

Design of experiments (DOE) is a systematic method to determine the

relationship between factors affecting a process and the output of that process. In
other words, it is used to find cause-and-effect relationships. This information is
needed to manage process inputs in order to optimize the output.

3.2 Central Composite Design

CCD is one of the most popular designs for fitting the second-order models.
Generally, the CCD consists of a 2k factorial design, 2k axial or star runs, and n
center runs.

Total runs = 2k+ (2*k) +nc, Where k = No of factors

The figure below (Fig 11) from shows the CCD for k = 2 and k = 3 factors.

(a)K=2 (b) K=3

Fig 3.2: Central Composite Design for two factors and three factors

28
 First, a 2k first order model is used. If the model shows a lack of fit, then axial
and center runs are added to incorporate the quadratic terms in the model. It is
important to select the value of α for the axial runs. If α = 1, the design is said to face-
centered. The number of center points is also to be selected. For a CCD with 3 input
parameters, 6 centre points are generally chosen to get 20 as the total number of runs
including 8 cube points (cube corners and 6 axial/star points (Fig b)

Even though three level designs help in understanding the nonlinear influence
of the process Parameters on the response, the number of experiments increases
tremendously with the increase in number of process parameters. For example, the
number of experiments involved in three level designs with three, four and five
factors is twenty seven (33=27), eighty one (34=81) and two hundred and forty three
(35=243), respectively. The principle of central composite rotatable design (CCD)
reduces the total number of experiments without a loss of generality. Is widely used as
it can provide a second order multiple regression model as a function of the
independent process parameters with the minimum Number of experimental runs .The
principle of central composite rotatable design includes 2k numbers of factorial
experiments to estimate the linear and the interaction effects of the independent
variables on the responses, where k is the number of factors or independent process
variables. In addition, a number (NC) of repetitions [nc>f] are made at the center point
of the design matrix to calculate the model independent estimate of the quadratic
terms into the model. The term rotatable indicates that the variance of the model
prediction would be the same at all points located equidistant from the center of the
design matrix.

The choice of the distance of the axial points (ζ) from the center of the design
is important to make a central composite design (CCD) rotatable. The value of ζ for
the ratability of the design scheme is estimated as ζ= (2f) 1/4
. The number of
experiments is estimated as

2k+ (2*k) +nc

The intermediate coded values are calculated as

* ( )+
Xi= ζ*

29
 Where xi is the coded value of a process variable (x) between x max and xmin.
For example the number of experiments in a CCD matrix corresponding to two
process variables is calculated as and the distance of the axial points from the center is
calculated as ζ = 22+ (2*2)+4=12 and the distance of the axial points from the center
is calculated as ζ=(2*2)1/4=1.414

Table 3.2: Depict the CCD for a two process parameter application.
Process Parameters (coded) Response Variable
Expt No.
Xi X2 y
1 -1 -1 Y1
2 1 -1 Y2
3 -1 1 Y3
4 1 1 Y4
5 -1.414 0 Y5
6 1.414 0 Y6
7 0 -1.414 Y7
8 0 1.414 Y8
9 0 0 Y9
10 0 0 Y10
11 0 0 Y11
12 0 0 Y12

3.3 Design of experiments

STEP 1: Create response surface design

30
STEP 2: Select CCD design, define the no of factors and the no of runs can be seen in
display available design option.

STEP 3: Select the appropriate design based on the requirement

31
STEP 4 Define Factors

STEP 5 Get the DOE as an output

32
 Table 3.2: Design Of Experiments

SPINDLE SPEED CUT DEPTH

RUN ORDER FEED (mm/min)
(R.P.M.) (mm)
1 270 0.13 0.3
2 830 0.13 0.3
3 270 0.2 0.3
4 830 0.2 0.3
5 270 0.13 0.5
6 830 0.13 0.5
7 270 0.2 0.5
8 830 0.2 0.5
9 270 0.18 0.4
10 830 0.18 0.4
11 540 0.13 0.4
12 540 0.2 0.4
13 540 0.18 0.3
14 540 0.18 0.5
15 540 0.18 0.4

[21]
D.I. Alani, N.K. Mehta, P.K. Jain did the investigation of the cutting
parameters on the cutting force and surface roughness. Machining experiments were
based on response surface methodology and the sequential approach was used using
central composite design. Twenty experimental runs composed of eight factorial
points with replication (16 runs), plus four center points were carried out in block 1
and 6 axial, plus 2 center points (8 runs) were carried out in block 2. In design matrix,
the coded variables were arranged as follows: A: cutting speed (V), B: feed rate (f)
and C: depth of cut (d). Fx, Fy, Fz and Ra are responses.

3.4 Summary

The most commonly used response surface designed experiment; Central

Composite Design (CCD) has been discussed. A full factorial face centered design
has been used to derive the design of experiments.
33
 CHAPTER 4

EXPERIMENTAL ANALYSIS

4.1 Experimental setup

Experiments were conducted to evaluate the machinability of cutting tool

while machining Inconel 625. A CNC Lathe was used for conducting the experiments
according to the Central Composite Design as shown in table 4.3(DOE table)

Fig 4.1: Experimental setup

Lathe tool dynamometer with digital Multicomponent force indicator was used
to determine the cutting force acting on the tool. After completing each experiment,
the cutting tool insert was removed and analyzed under Tool Maker‟s microscope to
measure tool flank wear. The obtained tool and flank wear were determined.

34
Experimental details are presented in Table 5.1. The experimentation for this work is
based on Central Composite Design (DOE) and Response Surface Methodology.
Inconel 625 was used as the work material

4.2 Machine tool (turning center lathe)

Fig 4.2: Conventional lathe machines

CHAMPIONS made All Geared Lathe Machine was used for carrying out the
experiment. The cutting parameters were selected as per the speed, feed and depth of
cut that were available on lathe machine.

4.2.1 Work specimen:

Table 4.2.1: Work specimen

Material Inconel 625

Size Ø60 X 180 mm

Hardness 220 HRB

35
4.2.2 Cutting tool

Cutting tool holder of WIDEX Company was used. The size of the tool holder
was selected such that it can fit in the dynamometer.

SVJNR 12 X 12 F12
WIDAX

Fig. 4.2.2: Cutting tool

4.2.3 Cutting insert

Double-sided 35° rhombic inserts for semi-finishing operations. Low cutting

forces due to very sharp edge and positive rake it is developed for machining of heat
resistant alloys, austenitic stainless steel and hard steel.

ISCAR VNMG12T308-Nf IC3028 GRADE: TIN/TiCN PVD COATED

36
KORLOY VNMG12T308-X100 PC9030 TiAlN PVD Coated

Fig 4.2.3(a): Cutting tool bit

l di S r

12.40 7.15 3.97 0.80

Double-sided 35° rhombic inserts for semi-finishing operations. Low cutting

forces due to very sharp edge and positive rake It is Developed for machining of heat
resistant alloys, austenitic stainless steel and hard steel. ISCAR's toughest coated
grade for machining stainless steel, high temperature alloys, at low to medium cutting
speed, used for interrupted cuts and very heavy machining.

Fig 4.2.3 (b): Geometry of tool bit

37
4.3 Lathe tool dynamometer

Tool Dynamometer that is used to measure one or more forces in

perpendicular and angular directions. Number of design factors has been considered
in manufacturing these dynamometers, such as the exact location of force, stiffness
required and the minimization of cross effects of force in one direction from the other.
Technology used in force measurement is highly stable strain gauge technique. The
strain gauges are employed in such a way that the independent bridge senses the
mutually perpendicular/angular force.

4.3.1 IEICOS Lathe tool dynamometer – model 621C: 500 KGF

This dynamometer sensor has been designed for measurement of forces on a

lathe machine during material processing. The proprietary design of the dynamometer
is such that the dynamometer can be directly fixed on the tool post using the hole
provided. Also, the tool bit can be directly mounted on the square hole provided at the
front of the sensor. The Lathe Tool Dynamometer can measure simultaneously 3
forces in mutually perpendicular directions, i.e. horizontal, vertical and thrust. No of
important points such as exact location of forces, stiffness required minimum cross
sensitivity (i.e. Minimization of effect of forces in one direction from other) have
been considered in design of the dynamometer.

Fig 4.3.1(a): Lathe tool dynamometer

38
 The direction of the positive force measurement for each of the three
directions is shown on the collector name plate mounted on the sensor on the top of
the connector block.

Fig 4.3.1(b): Dynamometer cable attachments

TABLE 4.3.1: Specification of lathe tool dynamometer

Model 621C

Range Of force 500 KgF

Directions X-horizontal Y-Vertical Z-Thrust

Sensor Type Strain Gauge

Sensor Resistance 350 ohms

Bridge Volume 10V DC Max

Accuracy <*/-1% of full scale

Linearity <+-1% of full scale

Repeatability <+-1% of full scale

39
4.3.2 IEICOS multi component digital force indicator 3 channel model 652

It consists of strain gauges signal conditioning units along the three digital
displays for the use with the dynamometer. It is calibrated with the Lathe Tool
Dynamometer sensor and hence is a matched pair.

The Force indicator is a self-contained unit which provides a self-contained

unit which provides excitation supply for the strain gauges on the dynamometer and
the three independent signal conditioning board along the digital display.

Fig. 4.3.2: multi component digital force indicator

Table 4.3.2: Specification of multi component digital force indicator

Model 652
No of channels 3
Sensor type (suited for Strain Gauge Strain gauge
Sensor Resistance 350 ohms
Accuracy <*/-1% of full scale
Linearity <*/-1% of full scale
Repeatability <*/-1% of full scale
Range (Calibrated to) 500 KgF
Resolution 1 KgF
Operating Voltage 230 V

40
4.4 Operating instructions:

Insert tool into the square hole of depth 30mm provided at the front of the
dynamometer and tighten the screw provided on the sensor with the help of hex Allen
key.

Fig. 4.3.3(a): Tool attachment with dynamometer

Mount the dynamometer on the lathe machine tool post using the central hole
provided on the dynamometer.

Fig. 4.3.2 (b): Dynamometer attachment with lathe

41
Ensure that the tool tip is at the center height of the specimen on the lathe machine. If
spacers are not used the spacers to adjust height.

 Connect the power 230 V 50 Hz D.C. supply.

 Connect the dynamometer to the force indicator sensor using the cable.
 Turn ON the Digital force indicator using the red switch.
 With no load applied the dynamometer sensor will indicate „000‟. Ensure the
READ/CAL switch is in the READ position.
 Use the CAL switch to calibrate. Display should show „500‟ reading if it is
properly calibrated.
 Indicator is ready to measure the forces on the lathe machine.

4.5 Tool maker’s microscope

A toolmaker‟s microscope is designed for measurements of parts of complex

forms, e.g. profile of external threads, tools, templates and gauges. It can also be used
for measuring center-to- enter distance of holes in any planes, as well as the co-
ordinate of the outline of a complex template gauge. Most of the uses of this
instrument will be on work where the shape of a profile is projected from below, but
surface shapes occur such as the edge of a recess, where surrounding metal prevents
light passing across the profile. These may be illuminated from above by a special
attachment, which then allows the profile to be received in the normal manner, except
that the intensity of light will be reduced from that received directly. It is an ideal
measuring instrument for simplifying inspection and precision measurement of
diameter, forming tools, gauges as well as template checking of thread and angles.
Tool maker microscope is a precision optical microscope having single or multiple
objective lens which magnifies the object under observation and by the help of
eyepiece lens the object is focused and viewed as shown in fig. 5.10. A high precision
micrometric X-Y stage and the Z axis travel is used to measure the three dimensions
[Length (X), Width (Y), Depth (Z)]. The angle is measured with the help of a circular
stage and eyepiece graduation. Circular stage is fitted on measuring stage, graduated
into 360° with dernier and lock.

42
The application of toolmaker‟s microscope may be summarized as follows:

1) Determination of the relative positions

2) Measurement of angles

3) Comparison measurement

4) Comparison with a scale

Fig 4.4: Tool maker’s microscope

Table 4.4: Specification of tool maker’s microscope

Eye Piece 30X Standard Magnification

Objective 2 X magnification
Field Of view 8 mm diameter
Working distance 115 mm approximately
150*150mm travel up to 25mm. In each
Measuring stage
direction having least count of 0.01mm

43
 Graduated 0 - 360⁰ with adjustable
Eyepiece Protractor
vernier of least count 6 minutes
Weight 8 kg
Total Magnification 30X to 50X

4.5 Industries/Institute visited

1. Central Institute Of Plastic Engineering - Ahmedabad

2. Indo German Tool room - Ahmedabad
3. Maharaj Sayajirao University - Baroda
4. Birla Vishwakarma Mahavidhyalaya – Vallabh Vidhyanagar

4.6 Summary
With the use of measuring instruments like lathe tool dynamometer and tool
maker‟s microscope experimental readings can be obtained. By performing the
experimental runs, the performance of the tool can be evaluated in terms of the feed
force, main cutting force and the flank wear of the cutting tool used. Variation of the
parameters like spindle speed, feed rate and depth of cut was done to study the effect
on the response.

44
 CHAPTER 5

RESULTS AND DISCUSSIONS

5.1 Experimental results

The cutting force was measured at IGTR while machining Inconel 625 and the
peak value during the machining was noted. Then the insert were observed under tool
maker‟s microscope and flank wear was determined.

Table 5.1: Experimental Results

Iscar - Korloy
Spindle Cut Iscar - Iscar - Korloy Korloy
Run Feed Flank Flank-
Speed Depth Fx Fy - Fx - Fy
No. (mm/min) Wear Wear
(rev/min) (mm) (KgF) (KgF) (KgF) (KgF)
(mm) (mm)
1 270 0.13 0.3 20 37 0.180 17 26 0.150
2 830 0.13 0.3 21 46 0.230 19 34 0.220
3 270 0.2 0.3 24 44 0.220 22 29 0.210
4 830 0.2 0.3 33 59 0.300 30 50 0.280
5 270 0.13 0.5 22 42 0.190 24 40 0.175
6 830 0.13 0.5 26 53 0.250 24 40 0.240
7 270 0.2 0.5 32 53 0.300 29 44 0.300
8 830 0.2 0.5 37 65 0.300 33 49 0.290
9 270 0.18 0.4 24 43 0.190 23 35 0.180
10 830 0.18 0.4 28 58 0.250 25 43 0.240
11 540 0.13 0.4 23 46 0.190 22 36 0.180
12 540 0.2 0.4 32 61 0.300 28 45 0.245
13 540 0.18 0.3 24 50 0.210 21 33 0.195
14 540 0.18 0.5 28 55 0.235 26 42 0.240
15 540 0.18 0.4 24 46 0.220 25 40 0.210

Fig. 5.1: Work piece after experiment

45
 Main cutting force, feed force and flank wear noted by varying the three
different input parameters at three different levels. The data was fed into Minitab® 17
to get following results listed below

5.2 Iscar Insert

5.2.1 ANNOVA and regression

The Analysis Of Variance (ANNOVA) shown in Table 5.2.1(a), Table

5.2.1(b) and Table 5.2.1(c) was used to study the significance and effect of the cutting
parameters on the response variables i.e. Main cutting force, feed force and flank
wear.

Table: 5.2.1(a) ANNOVA for Feed Force (Fx)

Source DF Adj SS Adj MS F-Value P-Value

Regression 9 336.039 37.3377 15.96 0.004
Vc 1 0.273 0.2726 0.12 0.747
F 1 27.454 27.4540 11.74 0.019
D 1 0.001 0.0011 0.00 0.983
Vc*Vc 1 0.053 0.0529 0.02 0.886
F*F 1 28.554 28.5541 12.21 0.017
D*D 1 0.006 0.0060 0.00 0.962
Vc*F 1 9.255 9.2555 3.96 0.103
F*D 1 2.709 2.7088 1.16 0.331
Vc*D 1 0.116 0.1163 0.05 0.832
Error 5 11.694 2.3388
Total 14 347.733

Model Summary

S R-sq R-sq(adj) R-sq(pred)

1.52930 96.64% 90.58% 47.16%

From Table 5.2.1(a), we can see that the P-value for the regression model is
0.004 which is lesser than the significance value of 0.05. Hence, the model is
significant. Feed is found to be the most influential parameter affecting the feed force
with the lowest P-value (0.019 significant) among all the three parameters.

46
 Table 5.2.1(b): ANNOVA for main cutting force (Fy)

Source DF Adj SS Adj MS F-Value P-Value

Regression 9 845.352 93.9280 8.66 0.014
Vc 1 10.660 10.6600 0.98 0.367
F 1 26.252 26.2519 2.42 0.181
D 1 0.311 0.3109 0.03 0.872
Vc*Vc 1 12.650 12.6502 1.17 0.330
F*F 1 30.982 30.9821 2.86 0.152
D*D 1 0.017 0.0167 0.00 0.970
Vc*F 1 8.582 8.5823 0.79 0.415
F*D 1 0.599 0.5990 0.06 0.824
Vc*D 1 0.291 0.2908 0.03 0.876
Error 5 54.255 10.8510
Total 14 899.607

Model Summary

S R-sq R-sq(adj) R-sq(pred)

3.29409 93.97% 83.11% 63.96%

From Table 5.2.1(b), we can see that the P-value for the regression model is
0.014 which is lesser than the significance value of 0.05. Hence, the model is
significant. Feed is found to be the most influential parameter affecting the main
cutting force with the lowest P-value (0.181 significant) among all the three
parameters.

Table 5.2.1(c): ANNOVA for main flank wears (Vb)

Source DF Adj SS Adj MS F-Value P-Value

Regression 9 0.025593 0.002844 7.68 0.019
Vc 1 0.000603 0.000603 1.63 0.258
F 1 0.003627 0.003627 9.80 0.026
D 1 0.000006 0.000006 0.02 0.903
Vc*Vc 1 0.000005 0.000005 0.01 0.910
F*F 1 0.004077 0.004077 11.02 0.021
D*D 1 0.000010 0.000010 0.03 0.879
Vc*F 1 0.000087 0.000087 0.24 0.648
F*D 1 0.000289 0.000289 0.78 0.418
Vc*D 1 0.000609 0.000609 1.64 0.256
Error 5 0.001851 0.000370
Total 14 0.027443

47
 Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.0192387 93.26% 81.12% 0.00%

From Table 5.2.1(c), we can see that the P-value for the model is 0.019 which
is lesser than the significance value of 0.05. Hence, the model is significant. Feed rate
is found to be the most influential parameter affecting the flank wear with the lowest
P-value (0.026 significant) among all the three parameters.

The main effect plot and the interaction effects plot for the Feed force, cutting
force and tool wear are shown in fig. 5.2.1 (a) to 5.2.1 (f).

Fig. 5.2.1(a): Main effect plot for feed force (Fx)

The feed force is affected by all the three parameters. Among all the
parameters there is a great change in feed force with increase in the feed. Large
amount of force is generated at feed of 0.2 mm/min and surface quality is highly
affected. The spindle speed affects the feed force less and is of no concern. Cut depth
has intermediate effect on feed force, large amount of forces are generated at 0.5 mm
depth of cut. There is less force variation of forces from 0.3 mm cut depth to 0.4 mm
cut depth as compared to 0.5 mm cut depth. From this graph we conclude that feed
force is affected mainly by feed rate taken followed by cut depth.

48
 Fig. 5.2.1(b): Interaction effect plot for feed force (Fx)

Fig 5.2.1(c): Main effect plot for main cutting force (Fy)

It can be concluded from the graph that even at low depth cut there is large
tangential force generated but with increasing cut depth less variation of force is
observed. There is a sharp increase in force by increasing spindle speed from 270
rev/min to 540 rev/min. A large variation in tangential force is observed by increasing
feed but the change observed is linear.

49
 Fig. 5.2.1(d): Interaction effect plot for main cutting force

Fig. 5.2.1(e): Main effect plot for flank wear (Vb)

It can be seen from the graph that spindle speed and flank wear shows more
increase in flank wear as compared to cut depth. For change in feed, wear is low at
0.13 mm/min and 0.18 mm/min but it increases suddenly due to large feed forces
generated and cutting force ratio is also large. There is an increase in flank wear with
the spindle speed. The wear increases more sharply at highest spindle speed. For 0.3

50
mm and 0.4 mm cut depth the flank wear observed has been close. With increasing
cut depth to 0.5 mm there is a sharp increase in flank wear.

Fig. 5.2.1(f): Interaction effect plot for flank wear

The regression coefficients obtained from MINITAB ®17 are laid out in Table
5.2.1(d), Table 5.2.1(e), and Table 5.2.1(f).

Table 5.2.1(d): Estimated coded regression coefficients for feed force (fx)

Term Coef SE Coef T-Value P-Value VIF

Constant 99.1 27.1 3.65 0.015
Vc -0.0062 0.0180 -0.34 0.747 109.04
F -1118 326 -3.43 0.019 592.17
D 1.8 81.3 0.02 0.983 282.53
Vc*Vc -0.000002 0.000012 -0.15 0.886 61.88
F*F 3410 976 3.49 0.017 564.48
D*D -4.8 95.4 -0.05 0.962 250.19
Vc*F 0.1078 0.0542 1.99 0.103 33.64
F*D 163 152 1.08 0.331 49.25
Vc*D -0.0043 0.0193 -0.22 0.832 25.79

Regression equation:

Fx-ISCAR = 99.1 - 0.0062 Vc - 1118 F + 1.8 D - 0.000002 Vc*Vc + 3410 F*F

4.8 D*D + 0.1078 Vc*F + 163 F*D - 0.0043 Vc*D

51
Table 5.2.1(e) Estimated coded regression coefficients for main cutting force (Fy)

Term Coef SE Coef T-Value P-Value VIF

Constant 95.8 58.4 1.64 0.162
Vc 0.0385 0.0388 0.99 0.367 109.04
F -1094 703 -1.56 0.181 592.17
D 30 175 0.17 0.872 282.53
Vc*Vc -0.000028 0.000026 -1.08 0.330 61.88
F*F 3552 2102 1.69 0.152 564.48
D*D -8 205 -0.04 0.970 250.19
Vc*F 0.104 0.117 0.89 0.415 33.64
F*D 77 327 0.23 0.824 49.25
Vc*D -0.0068 0.0416 -0.16 0.876 25.79

Regression equation:
Fy-ISCAR = 95.8 + 0.0385 Vc - 1094 F + 30 D - 0.000028 Vc*Vc +3552 F*F -
8 D*D + 0.104 Vc*F + 77 F*D - 0.0068 Vc*D

Table 5.2.1(f): Estimated coded regression coefficients for flank wear (Vb)

Term Coef SE Coef T-Value P-Value VIF

Constant 1.063 0.341 3.11 0.026
Vc 0.000290 0.000227 1.28 0.258 109.04
F -12.85 4.11 -3.13 0.026 592.17
D -0.13 1.02 -0.13 0.903 282.53
Vc*Vc -0.000000 0.000000 -0.12 0.910 61.88
F*F 40.7 12.3 3.32 0.021 564.48
D*D 0.19 1.20 0.16 0.879 250.19
Vc*F -0.000331 0.000682 -0.49 0.648 33.64
F*D 1.69 1.91 0.88 0.418 49.25
Vc*D -0.000311 0.000243 -1.28 0.256 25.79

Regression equation:

Vb-ISCAR = 1.063 + 0.000290 Vc - 12.85 F - 0.13 D - 0.000000 Vc*Vc + 40.7 F*F

+ 0.19 D*D - 0.000331 Vc*F + 1.69 F*D - 0.000311 Vc*D

52
5.2.2 Residual plots

Fig 5.2.2(a), Fig 5.2.2(b), Fig 5.2.2(c) display the residual plots for the
feed force, main cutting force and flank wear.

Fig. 5.2.2(a): Residual plots for feed force (Fx)

Fig. 5.2.2(b): Residual plots for main cutting force

53
 The model in fig. 5.2.2(a) is adequate as represented by the points falling on a
straight line in the normal probability plot. It shows that the errors are normally
distributed. Also, the plots of the residuals versus the predicted response are structure
less i.e. containing no obvious pattern which is desirable.

Again, the model in fig. 5.2.2(b) is adequate as represented by the points

falling on a straight line in the normal probability plot. It is an indication that the
errors are normally distributed which should be the case for a good-fit model. The
histogram also shows a nearly bell-shaped normal distribution. Also, the plot of the
residuals versus the predicted tool wear is structure less i.e. containing no obvious
pattern .

Fig. 5.2.2(c): Residual plots for flank wear (Vb)

Model in fig 5.2.2 (c) is adequate as represented by the points falling on a

straight line in the normal probability plot. It is an indication that the errors are
normally distributed which should be the case for a good-fit model. Also, the plot of
the residuals versus the predicted tool wear is structure less i.e. containing no obvious
pattern which is desirable.

54
5.2.3 Contour plots and 3-d surface plots

Contour and 3-D surface plots for feed force, main cutting force and flank we are
displayed in fig 5.2.3(a) to fig. 5.2.3(f).

Contour Plots of Fx-ISCAR

F*Vc D*Vc Fx-ISCAR
0.20 0.50
< 20.0
20.0 – 22.5
0.45
0.18 22.5 – 25.0
25.0 – 27.5
0.40 27.5 – 30.0
0.16
30.0 – 32.5
0.35 > 32.5
0.14
Hold Values
0.30
400 600 800 400 600 800
Vc 546
F 0.17
D*F D 0.4
0.50

0.45

0.40

0.35

0.30
0.14 0.16 0.18 0.20

Fig.5.2.3 (a): Contour plot of feed force (Fx)

Surface Plots of Fx-ISCAR

Hold Values
Vc 546
F 0.17
D 0.4
35 27. 5

Fx-I SCA R 30 Fx-I SCA R 25 .0

25 22.5
0. 200 0. 5
2 0 .0
20 0. 175 0 .4 D
F
0. 150
400 400 0.3
600 800 600 800
Vc Vc

35

Fx-I SCA R 30
25
0.5
20 0.4 D
0. 150 0 .3
0. 175
F 0. 200

Fig. 5.2.3 (b): 3-D Surface plot for Iscar (Fx)

55
 Contour Plots of Fy-ISCAR
F*Vc D*Vc Fy-ISCAR
0.20 0.50
< 40
40 – 45
0.45
0.18 45 – 50
50 – 55
0.40 55 – 60
0.16
> 60
0.35
0.14 Hold Values
Vc 546
0.30
400 600 800 400 600 800
F 0.17
D 0.4
D*F
0.50

0.45

0.40

0.35

0.30
0.14 0.16 0.18 0.20

Fig. 5.2.3(c): Contour plot of main cutting force (Fy)

Surface Plots of Fy-ISCAR

Hold Values
Vc 546
F 0.17
D 0.4

60 55

Fy-I SCA R Fy-I SCA R 50

50 45
0
0.200 0.5
40
40 0.17
17 5
F 0.4 D
0.1 5 0
400 400 0.3
600 800 600 800
Vc Vc

60
Fy-I SCA R 55
50
0. 5
45
0.4 D
0. 150
50 0.3
0.175
F 0 . 2 00

Fig. 5.2.3(d): 3-D surface plots of main cutting force (Fy)

56
 Contour Plots of Vb-ISCAR
F*Vc D*Vc Vb-ISCAR
0.20 0.50
< 0.18
0.18 – 0.21
0.45
0.18 0.21 – 0.24
0.24 – 0.27
0.40 0.27 – 0.30
0.16
> 0.30
0.35
0.14 Hold Values
Vc 546
0.30
400 600 800 400 600 800
F 0.17
D 0.4
D*F
0.50

0.45

0.40

0.35

0.30
0.14 0.16 0.18 0.20

Fig. 5.2.3(e): Contour plot of flank wear (Vb)

Surface Plots of Vb-ISCAR

Hold Values
Vc 546
F 0.17
D 0.4
0. 30 0.225
Vb-I SCA R 0 . 25 Vb-I SCA R 0.2 00
0. 20 0. 200 0. 175 0. 5
0. 15 0.17
175 0. 1 5 0 0. 4 D
F
0.150
400 40 0 0 .3
600 800 600 800
Vc Vc

0. 32
0.28
Vb-I SCA R
0. 24
0. 5
0. 20
0.4 D
0. 150 0. 3
0. 175
F 0. 200

Fig. 5.2.3(f): 3-D Surface plots of flank wear (Vb)

57
5.2.4 Optimum settings

The optimization plot is shown below in fig.5.2.4. The optimum cutting

variables for the responses to minimize were spindle speed of 270 rev/min, feed rate
of 0.1470 mm/min and depth of cut 0.3 mm. The plot shows how the desired response
(feed force, cutting force and flank wear) varies with increase in cutting speed, feed
and depth of cut. The value that maximizes the desirability gives the optimal settings.

In this research, multi-response optimization by desirability function of

response surface methodology has been used to find the optimal cutting parameters in
order to minimize the feed force, cutting force and flank wear. Each response is
converted into desirability functions. Desirability function has a range from 0 to 1.
Value of 1 indicates that the goal is achieved while zero means response is outside
acceptable region. The individual desirability functions are combined to obtain a final
desirability function.

Fig. 5.2.4: Optimization plot for Iscar Insert

58
 Table 5.2.4: Response optimization

Optimum conditions
Parameters Goal weight desirability
Lower Target Upper

Feed force
Minimum 20 20 37 1 1
(Fx)

Cutting
Minimum 37 37 64 1 1
force (Fy)

Flank wear
Minimum 0.18 0.18 0.3 1 1
(Vb)

5.3 Korloy Insert

5.3.1 ANNOVA and regression

The Analysis Of Variance (ANNOVA) shown in Table 5.3.1(a), Table 5.3.1(b) and
Table 5.3.1(c)) was used to study the significance and effect of the cutting parameters
on the response variables i.e. Main cutting force, feed force and flank wear.

Table 5.3.1(a): ANNOVA for feed force (fx)

Source DF Adj SS Adj MS F-Value P-Value

Regression 9 246.919 27.4355 28.49 0.001
Vc 1 0.041 0.0406 0.04 0.845
F 1 12.956 12.9564 13.46 0.014
D 1 3.108 3.1078 3.23 0.132
Vc*Vc 1 0.010 0.0103 0.01 0.922
F*F 1 15.799 15.7992 16.41 0.010
D*D 1 0.623 0.6229 0.65 0.458
Vc*F 1 10.930 10.9303 11.35 0.020
F*D 1 0.578 0.5781 0.60 0.473
Vc*D 1 4.487 4.4871 4.66 0.083
Error 5 4.814 0.9628
Total 14 251.733

Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.981238 98.09% 94.65% 82.50%

59
 From Table 5.3.1(a), we can see that the P-value for the model is 0.001 which
is lesser than the significance value of 0.05. Hence, the model is significant. Feed is
found to be the most influential parameter affecting the feed force with the lowest P-
value (0.0140 significant) among all the three parameters.

Table 5.3.1(b): ANNOVA for main cutting force (Fy)

Source DF Adj SS Adj MS F-Value P-Value

Regression 9 653.058 72.5620 30.55 0.001
Vc 1 4.483 4.4828 1.89 0.228
F 1 20.056 20.0558 8.44 0.034
D 1 24.604 24.6045 10.36 0.024
Vc*Vc 1 0.191 0.1913 0.08 0.788
F*F 1 24.123 24.1227 10.16 0.024
D*D 1 6.554 6.5542 2.76 0.158
Vc*F 1 38.169 38.1687 16.07 0.010
F*D 1 4.200 4.2000 1.77 0.241
Vc*D 1 72.171 72.1713 30.39 0.003
Error 5 11.875 2.3750
Total 14 664.933

Model Summary

S R-sq R-sq(adj) R-sq(pred)

1.54110 98.21% 95.00% 64.67%

From Table 5.3.1 (b), we can say that the p- value of the model is 0.001
which is less than the significance value of 0.05. Hence the model is significant. Feed
is the least influencing parameter among all the cutting parameters.

Table 5.3.1(c): ANNOVA for main flank wear (Vb)

Source DF Adj SS Adj MS F-Value P-Value

Regression 9 0.026560 0.002951 16.15 0.003
Vc 1 0.000735 0.000735 4.02 0.101
F 1 0.001121 0.001121 6.14 0.056
D 1 0.000353 0.000353 1.93 0.223
Vc*Vc 1 0.000063 0.000063 0.35 0.581
F*F 1 0.001392 0.001392 7.62 0.040
D*D 1 0.000453 0.000453 2.48 0.176
Vc*F 1 0.000606 0.000606 3.32 0.128
F*D 1 0.000402 0.000402 2.20 0.198
Vc*D 1 0.000905 0.000905 4.95 0.077
Error 5 0.000913 0.000183
Total 14 0.027473

60
 Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.0135159 96.68% 90.69% 28.81%

From Table 5.3.1(c), we can see that the P-value for the model is 0.003 which is lesser
than the significance value of 0.05. Hence, the model is significant. Depth of cut is
found to be the most influential parameter affecting the flank wear with the lowest P-
value (0.056 significant) among all the three parameters.

The main effect plot and the interaction effects plot for the surface roughness and tool
wear are shown in fig. 5.3.1(a) to 5.3.1(f)

Fig. 5.3.1(a): Main effect plot for feed force

Feed Force increases gradually and is less affected by spindle speed as the
graph obtained is linear and of fewer slopes. At 0.13 mm/min the feed force is less
with increase in the feed there is a sharp increase in the force. Cut depth affects feed
force but the feed force doesn‟t increase sharp as compared to feed rate by increasing
the parameters.

61
 Fig. 5.3.1(b): Interaction effect plot for feed force (Fx)

Fig. 5.3.1(b): Main effect plot for main cutting force (Fy)

It can be seen that there is sharp increase in tangential force while increasing
the cut depth from 0.3 mm to 0.4 mm as compared to increase from 0.4 mm to 0.5
mm cut depth. The increase of force with spindle speed is linear. It can be concluded
that depth of cut and feed force are major parameters affecting tangential force

62
 Fig. 5.3.1(d): Interaction effect plot for main cutting force (Fy)

Fig. 5.3.1(e): Main effect plot for flank wear (Vb)

The Flank wear shows more sharp increase when cutting parameters are
changed from 540 rev/min to 840 rev/min. Even at high feed rate 0.2 mm/min large
wear is observed. At 0.3 mm and 0.4 mm cut depth the wear was observed to be
equivalent but sharp increase was observed at 0.5 mm cut depth

63
 Fig. 5.3.1(f): Interaction effect plot for flank wear (Vb)

The regression coefficients obtained from MINITAB ®17 are laid out in Table
5.3.1(d), Table 5.3.1(e) and Table 5.3.1(f).

Table 5.3.1(d): Estimated coded regression coefficients for feed force (Fx)

Term Coef SE Coef T-Value P-Value VIF

Constant 52.0 17.4 2.99 0.030
Vc -0.0024 0.0116 -0.21 0.845 109.04
F -768 209 -3.67 0.014 592.17
D 93.7 52.2 1.80 0.132 282.53
Vc*Vc -0.000001 0.000008 -0.10 0.922 61.88
F*F 2537 626 4.05 0.010 564.48
D*D -49.2 61.2 -0.80 0.458 250.19
Vc*F 0.1171 0.0348 3.37 0.020 33.64
F*D -75.4 97.3 -0.77 0.473 49.25
Vc*D -0.0267 0.0124 -2.16 0.083 25.79

Regression equation:

Fx-KORLOY = 52.0 - 0.0024 Vc - 768 F + 93.7 D - 0.000001 Vc*Vc + 2537 F*F -

49.2 D*D + 0.1171 Vc*F - 75.4 F*D - 0.0267 Vc*D

64
Table 5.3.1(e): Estimated coded regression coefficients for main cutting force (fy)

Term Coef SE Coef T-Value P-Value VIF

Constant 33.9 27.3 1.24 0.270
Vc 0.0250 0.0182 1.37 0.228 109.04
F -956 329 -2.91 0.034 592.17
D 263.7 81.9 3.22 0.024 282.53
Vc*Vc -0.000003 0.000012 -0.28 0.788 61.88
F*F 3134 983 3.19 0.024 564.48
D*D -159.7 96.1 -1.66 0.158 250.19
Vc*F 0.2189 0.0546 4.01 0.010 33.64
F*D -203 153 -1.33 0.241 49.25
Vc*D -0.1073 0.0195 -5.51 0.003 25.79

Regression equation:

Fy-KORLOY = 33.9 + 0.0250 Vc - 956 F + 263.7 D - 0.000003 Vc*Vc + 3134 F*F -

159.7 D*D + 0.2189 Vc*F - 203 F*D - 0.1073 Vc*D

Table 5.3.1(f): Estimated coded regression coefficients for flank wear (Vb)

Term Coef SE Coef T-Value P-Value VIF

Constant 0.740 0.240 3.08 0.027
Vc 0.000320 0.000159 2.01 0.101 109.04
F -7.15 2.88 -2.48 0.056 592.17
D -0.998 0.718 -1.39 0.223 282.53
Vc*Vc 0.000000 0.000000 0.59 0.581 61.88
F*F 23.81 8.63 2.76 0.040 564.48
D*D 1.328 0.843 1.57 0.176 250.19
Vc*F -0.000872 0.000479 -1.82 0.128 33.64
F*D 1.99 1.34 1.48 0.198 49.25
Vc*D -0.000380 0.000171 -2.23 0.077 25.79

Regression equation:

Vb-KORLOY = 0.740 + 0.000320 Vc - 7.15 F - 0.998 D + 0.000 Vc*Vc+ 23.81 F*F

+ 1.328 D*D - 0.000872 Vc*F + 1.99 F*D - 0.000380 Vc*D

65
5.3.2 Residual plots

Fig 5.3.2(a), Fig 5.3.2(b), Fig 5.3.2(c) display the residual plots for the feed force,
main cutting force and flank wear.

Fig. 5.2.3(a): Residual plots for feed force (Fx)

Fig.5.3.2 (b): Residual plots for main cutting force (Fy)

66
 Again, the model in fig. 5.2.3 (a) is adequate as represented by the points
falling on a straight line in the normal probability plot. It is an indication that the
errors are normally distributed which should be the case for a good-fit model. The
histogram also shows a nearly bell-shaped normal distribution. Also, the plot of the
residuals versus the predicted tool wear is structure less i.e. containing no obvious
pattern

Again, the model in fig. 5.2.3 (b) is adequate as represented by the points
falling on a straight line in the normal probability plot. It is an indication that the
errors are normally distributed which should be the case for a good-fit model. The
histogram also shows a nearly bell-shaped normal distribution. Also, the plot of the
residuals versus the predicted tool wear is structure less i.e. containing no obvious
pattern

Fig. 5.3.2(c): Residual plots for flank wear (vb)

The model in fig. 5.2.3(c) is adequate as represented by the points falling on a

straight line in the normal probability plot. It is an indication that the errors are
normally distributed which should be the case for a good-fit model. Also, the plot of
the residuals versus the predicted tool wear is structure less i.e. containing no obvious
pattern

67
5.3.3 Contour plots and 3-D surface plots

Contour and 3-D surface plots for feed force, main cutting force and flank
we are displayed in Fig. 5.3.3(a) to Fig 5.3.3(f).

Contour Plots of Fx-KORLOY

F*Vc D*Vc Fx-KORLOY
0.20 0.50
< 18
18 – 20
0.45
0.18 20 – 22
22 – 24
0.40 24 – 26
0.16
26 – 28
0.35 28 – 30
0.14 > 30
0.30
400 600 800 400 600 800
Hold Values
Vc 546
D*F F 0.17
0.50
D 0.4

0.45

0.40

0.35

0.30
0.14 0.16 0.18 0.20

Fig.5.3.3 (a): Contour plot of feed force (Fx)

Surface Plots of Fx-KORLOY

Hold Values
Vc 546.666666666667
F 0.17
D 0.4
32 27

28 24
F x-K OR L OY F x-K OR L OY
21
24 0 .5
0 .2 0 0
0.17
17 5 18
20 0 .4
0.1 5 0 F D
400 400
600 600 0.3
Vc 800 Vc 800

32

28
F x-K OR L OY2 4
0 .5
20
0 .4
D
0 .1 5 0 0.3
0.1 75
F 0.2 0 0

Fig. 5.3.3 (b): 3-D surface plots of feed force (Fx)

68
 Contour Plots of Fy-KORLOY
F*Vc D*Vc Fy-KORLOY
0.20 0.50
< 25
25 – 30
0.45
0.18 30 – 35
35 – 40
0.40 40 – 45
0.16
45 – 50
0.35 > 50
0.14
Hold Values
0.30
400 600 800 400 600 800
Vc 546
F 0.17
D*F D 0.4
0.50

0.45

0.40

0.35

0.30
0.14 0.16 0.18 0.20

Fig. 5.3.3(c): Contour plot of main cutting force (Fy)

Surface Plots of Fy-KORLOY

Hold Values
Vc 546
F 0.17
D 0.4
50 40
Fy-KORLOY 45 Fy-KORLOY 35
40
0. 200 30 0.5
35
0 . 175
7 25
F 0. 4 D
0 .150
400 400 0.3
600 800 600 800
Vc Vc

45
Fy-KORLOY 40
35 0. 5
30
0. 4 D
0.150
0 0. 3
0. 175
F 0 . 200

Fig. 5.3.3(d): 3-D surface plots of main cutting force (Fy)

69
 Contour Plots of Vb-KORLOY
F*Vc D*Vc Vb-KORLOY
0.20 0.50
< 0.150
0.150 – 0.175
0.45
0.18 0.175 – 0.200
0.200 – 0.225
0.40 0.225 – 0.250
0.16
0.250 – 0.275
0.35 > 0.275
0.14
Hold Values
0.30
400 600 800 400 600 800
Vc 546
F 0.17
D*F D 0.4
0.50

0.45

0.40

0.35

0.30
0.14 0.16 0.18 0.20

Fig. 5.3.3 (e): Contour plot of flank wear (Vb)

Surface Plots of Vb-KORLOY

Hold Values
Vc 546
F 0.17
D 0.4

0. 25 0.225
Vb-KORLOY b-KORLOY
0. 200
0. 20
0. 200 0.175 0.5
0.15 0. 175 0.150 0.4 D
F
0 . 150
400 400 0. 3
600 800 600 800
Vc Vc

0 . 30

b-KORLOY0.25

0 . 20 0. 5
0.4 D
0. 150 0. 3
0. 1 75
F 0.200

Fig. 5.3.3 (f): 3-D surface plots of flank wear (Vb)

70
5.3.4 Optimum settings

The optimization plot is shown below in fig.5.3.4 below. The optimum cutting
variables for the responses to minimize were spindle speed of 270 rev/min, feed rate
of 0.1427 mm/min and depth of cut 0.3 mm. The plot shows how the desired response
(feed force, cutting force and flank wear) varies with increase in cutting speed, feed
and depth of cut. The value that maximizes the desirability gives the optimal settings.

Fig. 5.3.4: Optimization plot for Korloy Insert

The plot shows how the desired response (feed force, cutting force and flank wear)
varies with increase in cutting speed, feed and depth of cut. The value that maximizes
the desirability gives the optimal settings. The optimization plot is shown below in
fig.5.3.4 below. The plot shows how the desired response (feed force, cutting force
and flank wear) varies with increase in cutting speed, feed and depth of cut. The value
that maximizes the desirability gives the optimal settings.

71
5.4 Comparison of flank wear

COMPARISON OF FLANK WEAR

Iscar Korloy

0.35

0.3 0.300
0.3 0.3 0.3
0.3 0.290
0.280

0.25 0.25
0.245
0.25 0.240 0.240 0.240
0.235
0.23
0.220 0.22 0.22
0.210 0.21 0.210
0.195
FLANK WEAR ()MM

0.2 0.19 0.19 0.19

0.18 0.180 0.180
0.175

0.150
0.15

0.1

0.05

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Iscar 0.18 0.23 0.22 0.3 0.19 0.25 0.3 0.3 0.19 0.25 0.19 0.3 0.21 0.235 0.22
Korloy 0.150 0.220 0.210 0.280 0.175 0.240 0.300 0.290 0.180 0.240 0.180 0.245 0.195 0.240 0.210
EXPERIMENTAL RUNS

It can be concluded from the graph that Korloy Insert shows more resistance to flank
wear as compared to Iscar insert. Hence they can provide longer tool life.

72
5.5 Cutting Force graphical representation

5.5.1 Iscar Insert

Iscar Cutting Force

65

Force (KgF)
80 59 53 53 58 61 55
46 44 42 43 46 50 46
60 37 33 32 37 28 32 28
20 21 24 22 26 24 23 24 24
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Feed Force (Fx) 20 21 24 33 22 26 32 37 24 28 23 32 24 28 24
Tangential Force (Fy) 37 46 44 59 42 53 53 65 43 58 46 61 50 55 46
Experimental Runs

Feed Force (Fx) Tangential Force (Fy)

5.5.2 Korloy Insert

Korloy Cutting Force

60 50 49 45
40 40 44 43 42 40
50 34 33 35 36 33
40 26 29 30 29 25 28 26 25
24 24
Force (KgF)

19 22 23 22 21
30 17
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Feed Force (Fx) 17 19 22 30 24 24 29 33 23 25 22 28 21 26 25
Tangential Force (Fy) 26 34 29 50 40 40 44 49 35 43 36 45 33 42 40
Experimental runs

Feed Force (Fx) Tangential Force (Fy)

5.6 Summary

Based on the experimental results the relationship between the machining

parameter and the output response were modeled by response surface methodology
(RSM). Analysis of Variance (ANNOVA) was performed to check the adequacy of
the mathematical model and its respective variables. Main effect plot, Interaction plot,
contour plot and 3-D surface plots were obtained to study the effect of the machining
parameters on the response. Quadratic mathematical model were developed to obtain
a mathematical relation between the response and the machining parameters. Normal
probability plot and residual vs. fit plots were plotted.

73
 CONCLUSION

The machining of Super alloy, Inconel 625 was carried out by orthogonal
turning process in a dry environment. Two cutting inserts of same geometry with
different grade of PVD coating, Iscar insert with TiN/TiCN and Korloy with TiAlN
coating were used for machining.

CCD was used to design experimental runs where cutting parameters spindle
speed, feed rate and depth of cut were varied and response feed force, cutting force
and flank wear were measured. With the application of RSM quadratic model was
developed to obtain relation between cutting parameters and response. ANNOVA was
used to check the significance of the model. Main effect plot, Interaction plot,
Contour plot, 3-D surface plots and Optimization plot were obtained.

Based on the experimental results discussed and presented, following

conclusions are drawn.

 Feed rate is the most dominating factor among all the cutting parameters
followed by depth of cut. Large feed rate shows sudden increase in the cutting
force. Spindle speed has less effect on response.
 Higher feed rate and depth of cut shows sharp increase in tool wear as at that
point the cutting forces generated are very large, leading to more flank wear.
 The quadratic models were found to be significant with the P-value of 0.004,
0.014 and 0.019 for Iscar insert and 0.001, 0.001 and 0.003 for Korloy insert.
 For Iscar Insert with TiN/TiCN grade, from the response surface optimization
plot the optimum combination of machining parameters are spindle speed =
270 rev/min, feed = 0.1470 mm/min and depth of cut = 0.30mm.
 For Korloy Insert with TiAlN grade, from the response surface optimization
plot the optimum combination of machining parameters are spindle speed =
270 rev/min, feed = 0.1427 mm/min and depth of cut = 0.30mm.
 Less flank wear and cutting forces were generated in Korloy insert (TiAlN
PVD coated) as compared to Iscar insert (TiN/TiCN PVD coated). Among the
PVD coated tools TiAlN coating showed better results as compared to
TiN/TiCN coated tools.
 In case of dry turning operation low spindle speed are preferred.

74
 The analysis of the results revealed that the optimum combination of low feed
rate and depth of cut are beneficial for reducing the cutting force with less
significance of spindle speed.

75
 FUTURE SCOPE

The present work features the dry turning of Inconel 625 by varying spindle
speed, feed and depth of cut and getting feed force, cutting force and flank wear as
response. Two different PVD coated insert were used.

More input parameters such as changing tool geometry or doing oblique cutting
can be done instead of performing orthogonal cutting process. Responses such as
vibration on the cutting tool can also be measured. Different cutting environment such
as using MQL (Minimum quantity lubrication) can be employed or hybrid coolants
can be used to check the changes in the response.

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 NOMENCLATURE

BUE Built Up Edge

MQL Minimum Quantity Lubrication

DOE Design of Experiments

CCD Central Composite Design

ANNOVA Analysis of Variance

RSM Response Surface Methodology

PVD Physical Vapor Deposition

CVD Chemical Vapor Deposition

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 APPENDIX

APPENDIX 1: Symbols

Fx= Feed force (Horizontal force)

Fy= Main cutting force (Tangential force)

Fz= Radial force

Vc= Spindle Speed

F = Feed rate

D = Depth of Cut

APPENDIX 2: Research paper presented/published

1. Published a research paper on “Investigation of Cutting Force and Tool Wear

behavior In Dry Turning of Inconel 625” in International Journal of Advance
Engineering and Research Development (IJAERD) Volume-2, Issue-05 of
May 2015. Page 539-547

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