ABSTRACT

The potential of Austempered Ductile Iron (ADI) as an engineered material is no

longer questionable; however, inadequate information on the machinability of this
material has limited possible applications of ADI. In this research, machining
recommendations for the commercial grades of ADI have been developed. The
influence of ausferrite matrix plastic deformation and material transformation in the
machining affected zone (MAZ) has been characterized.

Machining studies of ADI were performed for common machining operations such
as milling, turning and drilling under production machining conditions. The data
collected in these experiments consisted of tool wear measurements, surface
roughness characterization, and the chip formation during machining. Tool wear
measurement data were used to generate initial machining recommendations for
Grade 1 ADI, Grade 2 ADI, and Grade 3 ADI based on tool life estimation. The
effects of cutting parameters on surface roughness and chip formation of ADI were
also analyzed. Finally, microhardness, metallography, and scanning electron
microscopy (SEM) characterization were used to understand the phenomena of
strain induced plasticity and transformation during the machining of ADI to lead to
an improved understanding of the machinability of ADI.

Machining trials, based on tool wear measurement data, were evaluated to generate
predictive tool life equations based on Taylor tool life models. These models were
used to estimate starting machining parameters for each grade of ADI as well as
guidelines for machining parameter adjustments based on tool life. ADIs should be
machined at 25% lower cutting speeds than conventional steels with comparable
bulk hardness. Similarly, appropriate cutting speed for machining the widely used
Grade 1 ADI are 25% lower than cutting speeds used for grade 100- 70-03 as-cast
ductile iron. Within the various grades of ADI, recommended machining guidelines
are inversely proportional to ADI hardness. The specific cutting forces showed that
ADIs are similar to the range of specific cutting forces kc1 for ISO-H (hardened
steel).
Experimental Study of Tool Chip Contact and Chip Formation in Machining of ADI

Chapter 1
INTRODUCTION
Austempered Ductile Iron (ADI) offers excellent mechanical properties, such as high
strength-to- weight ratio, toughness, wear resistance and fatigue strength, in comparison
to cast and forged aluminum and many cast and forged steels. Despite the potential of
ADI as an engineered material, this material is often not considered when designing a
component due to inadequate information on its machinability. Considering how essential
machining operations are for a casting to meet the final dimensional and tolerance
requirements, it is not surprising that this lack of fundamental machining guidelines has
limited further applications of ADI.

1.1 Statement of the Problem

A lack of information of machining of ADI is a startling fact in light of the growing
interest in the use of ADI as an engineered material.

While machinists often refer to the machining handbooks or the machining

recommendations provided by cutting tool companies to obtain starting parameters to
machine a material, this information is not available when it comes to ADI. In addition,
existing knowledge on the machining of the commercial ADI grades possessed by
machine shops is tightly held and is not available in the public domain. Therefore, it is
important to develop an accessible starting recommendation on machining of ADI to
allow further applications of this low cast, high performance material.

Machining recommendations are constructed to assure sufficient tool life which directly
impacts machining cost and acceptable machined surface finish. Tool life and surface
finish are used as two main criteria in generating these recommendations. The chip
formation is not a main concern when machining ADI because short discontinuous chips
are formed instead of long continuous chips, which might tangle and damage the cutting
tool and the workpiece. Nevertheless, a detailed assessment on the shape, size and color
of ADI chips should be done to investigate whether chip analysis can be used as a rapid
means to determine appropriate cutting parameters of ADI.

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1.2 Scope of Work

The general objectives of this research project are to conduct comprehensive tool
wear studies on the commercial grades of ADI for milling, turning, and drilling and
to develop initial machining recommendations for these grades of materials.
In specific, this research effort includes:

 Review of the available information and existing knowledge on machining of ADI

 Machining (face milling, turning and drilling) trials of ADI at different cutting
parameters to collect machining data, such as tool life, surface roughness and
chip formation
 Analysis of the machining data to provide starting recommendations to machine
ADI based on machinability criteria (i.e. average tool life, minimum surface
roughness, etc.)
 Investigation of the possibility of using surface finish appearance and chips
formed as a rapid approach to determine whether a cutting parameter is
“acceptable” or not

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Chapter 2

AUSTEMPERED DUCTILE IRON

A brief introduction of Austempered Ductile Iron is discussed in this chapter. The

necessary requirements to produce high quality ductile iron castings to ensure ADI
success after heat treatment are first described. Then, the standard grades of ADI
per ASTM A897/A897M-16 are presented along with some examples of the use of
this material in engineering applications. In order to fully understand the standard
grades of ADI, it is also important to discuss the heat treatment stages of ADI
production.

2.1. Ductile Cast Iron Requirements for ADI Success

Austempering, like other heat treatment process, is performed to enhance the
properties of ductile iron castings. However, austempering is not a fix for poor
quality ductile iron. Tight quality controls on ductile iron alloying elements and
production processes are essential to produce ADI with superior mechanical
properties and appropriate microstructures. The quality of ADI not only affects the
mechanical performance of this material but also dictates its machinability.
Therefore, the criteria of producing good ductile iron as suggested by Hayrynen
will be briefly discussed in this section as a starting point for understanding ADI.
Careful control of chemical composition is important to produce high quality
ductile iron. Controls of carbon and silicon are necessary to meet Carbon
Equivalent (CE) requirements. Silicon, furthermore, influences the Upper Critical
Temperature (UCT) of the phase diagram. Increasing the UCT means that
austenitizing must be done at a higher temperature. While the addition of silicon
raises the UCT, manganese lowers this critical temperature. On the other hand,
excess manganese may result in martensite formation caused by low austenite
carbon content in the segregated regions of the ductile iron microstructure. Copper,
nickel and molybdenum can be added for hardenability purposes, i.e. avoiding
the pearlite nose during rapid cooling from austenitizing to the austempering
step. Excess additions of these elements can be detrimental to heat treatment
success.

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2.2 Production of ADI

Producing high quality ADI castings is not trivial matter. Careful planning and
proper procedures must be followed during initial casting to produce satisfactory
outcomes after heat treatment. A typical heat treatment process flow summary for
ADI production is shown in Figure 2-1.

Figure 2-1: Commercial Austempered Ductile Iron heat treatment process cycle

When the parts are scheduled to be heat-treated, the components must be arranged
in furnace baskets in such a way that the shape of the parts is maintained, and that
the circulation of molten salt during the quench is optimum. The component
arrangement is also critical to ensure that no phase transformation occurs during the
transfer from the furnace to the salt quench tank and during cooling to the
austempering temperature.
After a batch of parts are loaded, a preheating operation is often performed prior to
austenitizing. In addition to serving as a mild stress reliever, the preheating also
provides better energy recovery in the austenitizing furnace. Since preheating is
done at a temperature between 900-1100ᴼF (482- 593ᴼC), the heat-up time in the
austenitizing chamber will be reduced. Unlike the austenitizing process, preheating
can be done in an open-air furnace without the concern of scale formation at this
lower processing temperature.

After preheat, the components will then enter the austenitizing chamber which must
contain a protective atmosphere to avoid the formation of an oxide scale and/or
decarburization. Furthermore, endothermic gases, produced from a mixture of

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natural gas (CH4) and air (N2 and O2) used as heat source, prevent surface
decarburization during austempering.

A typical complete austempering cycle is shown in Figure 2-2. After preheating, the
components is raised to the austenitizing temperature (A to B) and austenitized in a
controlled atmosphere (B to C). After holding at the austenitizing time, the components are
quenched (C to D) to the austempering temperature in a bath of molten salt. Isothermal
heat treatment (D to E) is then done at a chosen austempering temperature for a
predetermined austempering time. The components are then cooled to room temperature (E
to F) to complete the ADI heat treatment cycle.

Figure 2-2: A schematic of the austempering process

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Chapter 3

LITERATURE SURVEY

1. Austempered Ductile Iron Machining.

Author: Jozef Pilc, Michal Sajgalí, Jozef Holubjak, Marianna Piesova.
Year: 2015
In the meantime a ADI has been used as a alternative for present steel forgings,
workpieces, sciliced by the changed construction or with it´s small forming. The
alternative of steel - castings from ADI is so far the most common way of
application of ADI, which is directing to the decreasing of the production costs,
that means to the savings on a price or to increasing the componet´s life cycle.
From the properties of ADI is by such as mentioned alteratives used especially
very good resistance of wear and tear, which is in comparison with the steel
(which has the same hardness) about double so high.Before indicating some
applications of ADI it is important to remember some physical characteristics,
which combined with the mechanical properties of ADI, open the market for this
material in many different industries, but particularly for automotive components.

2. Understanding The Machinability of Austempered Ductile

Iron (Adi).
Author: Dika Handayani, Robert C. Voigt, and Kathy Hayrynen.
Year:2018
Comprehensive machining recommendations for the commercial grades of ADI
have been generated. This information is critical to drive further applications of
ADI as an engineering material. Strain-induced martensitic transformation of the
ausferrite is observed on prior machined surfaces. Sufficient depth of cut and feed
rate must be used when machining ADI to not only maintain the cut below the
surface martensitic layer but also below the work-hardened layer toavoid lower
tool life during subsequent passes.
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3. Machinability Related Issues of Austempered Ductile Iron.

Author: Sushant Shastri Dr. P.P.Parhad.

Year:2015
Extensive research work on the ADI has led to the development of different
grades of ADI focusing on improving ductility, tensile strength, wear resistance
and machinability. Machinability for grade 1200 of ADI was found to have good
machinability index with greater signs of work hardening compared to other
grades. With advantageous properties and lowercost ADI offers a wide range of
scope to be used in industrial applications.

4. Machining Characteristics of Austempered Ductile Iron.

Author: Ashwin Polishetty, Sarat Singamneni, Guy Littlefair.
Year:2008
The drilling trials conducted on ADI grades900, 1050, 1200 and 1400 have
yielded the following
results in support of machining characteristics of ADI.
The cutting force analysis has shown that the cutting force varied according to the
hardness of the ADI grades and increased proportionately. The moments remained
almost constant for all the grades of ADI. The effect of using cutting fluid on all
the grades of ADI can be observed as the holes machined using coolant had a
good surface finish when compared to holes machined without coolant. The
variations observed in surface roughness (Ra) values tally with the microhardness
variations indicating a basic principle in machining as the hardness increases, the
Ra value increases .The metallography analysis reveals that there was no
microstructural changes due to drilling at the chosen speeds, rpm (697 and 929)
and feed rates, mm/rev (0.1 and 0.2).5 The results obtained in each of the test
conducted to determine the machinability characteristics of ADI imply that the
chosen speeds and federate were not effective in triggering a change in the
machining characteristics of ADI.

5. Determination Experimental of Machining Responses in

Machining Austempered Ductile Iron (Adi).

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Author: Kumar K.M, Hariharan P.
Year: 2013

This experiment was conducted to find the influence of the peak current, pulse on
time, pulse off time, tool geometry and austempering temperature on the EDM
performance characteristics of ADI material with copper electrode. It was also
tried to formulate a mathematical model for the responses MRR, TWR, Surface
Roughness (SR) and taper angle (DVEE). The conclusions from the analysis of
these experimental results can be specified as follows:
1. Based on the experimental values, the current and pulse off time are the most
significant and critical
process parameters that affect all the responses, except MRR and DVEE.
2. The MRR and TWR increases with increasing current and pulse on time, but
the surface roughness and DVEE inversely affect by increasing these two
parameters.
3. Tool geometry does not have any reasonable influences in all the responses.
However the DVEE increasing with increase the tool cross section area.
4. Austempering temperature influences only in surface roughness of the material.
It was found that inversely proportionate with surface roughness.

6. Machinability And Related Properties of Austempered

Ductile Iron.
Author: Ananda Hegde, Sathyashankara Sharmaand, Gowri Shankar
M.C.
Year:2018
ADI has good mechanical properties, but its machinability is a great concern for
the researchers. The main problem faced during the machining of ADI is the strain
induced transformation of austenite to martensite phase which reduces the tool life
significantly. It is very important to restrict the amount of alloying elements added
especially manganese and molybdenum in order to prevent strain induced
transformation during machining. High nodule count is always preferred as it
prevents the strain induced transformation. Higher depth of cut is preferred as it
helps to machine efficiently in the case of strain induced transformation. Even

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though there is a great concern regarding the machinability of ADI, by selecting
the appropriate tool with appropriate machining parameters, ADI can be machined
successfully.

7. The Experimental Investigations into Dry Turning of

Austempered Ductile Iron.
Author: Narendra bhople, Nelesh patil, Sachin patil.
Year:2018
In the present work, experimental investigations on dry turning of ADI have been
undertaken.
Based on findings of this study, following conclusions can be drawn.
1. Analysis of variance (ANOVA) shows depth of cut is important parameter for
main cutting force followed by feed rate. Increased depth of cut and feed
generated higher cutting forces due to increased shear area . Main cutting force
has been found to vary from 52.87 N to 264.6 N. The R-squared value for main
cutting force has found to be 0.9590.
2. Cutting speed and feed play vital role for surface roughness, ANOVA shows
cutting speed has greater influence on values of surface roughness. Greater cutting
speed and lower feed exhibited superior surface finish, due to the elimination of
built up edge at higher cutting speed. The R-squared value for Ra was found to be
0.9288.
3. At lower depth of cut hardness of the surface increased than bulk hardness, this
indicates occurrence of SIT. At higher depth of cut tool avoid facing newly
formed surface, causing relatively low hardness.

8. Characteristics Of Tempering Response Of Austempered

Ductile Iron.
Author: Bingxu Wanga,, Gary C. Barbera, Chuanlin Tao.
Year:2017
In this research, several tempering temperatures were applied on ADI samples
produced by three different austempering temperatures. After investigating the
hardness and microstructure, several conclusions can be drawn:- The hardness of
ADI samples decreases with increasing austempering temperature at the same

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holding time, and also decreases with increasing tempering temperature foreach
austempering condition.

The ADI samples austempered at 373◦C have thick feather-like ausferrite, but thin
needle-like ausferrite is formed for276◦C and 321◦C austempering temperatures.
The ausferritic structure is gradually decomposed into dispersive cementite
particles with higher tempering temperatures. There is very little needle-like
component which still exists at and above 538◦C tempering temperature for
ductile iron samples austempered at 276◦C and 321◦C. Also there is only a small
amount of feather-like component existing at and above 482◦C tempering
temperature for ductile iron samples austempered at 373◦C.- The above results
related to hardness and microstructure are important for selecting proper
tempering temperatures and should also be considered when applying case
harden-ing processes, such as nitriding treatment (500–600◦C) and
nitrocarburizing treatment (530–600◦C).

9. High Performance Turning Of Austempered Ductile Iron

(Adi).
Author: M.Arft a, F.Klocke.
Year:2013
In the presented study the difficult to machine material Austempered Ductile Iron
(ADI) was investigated. First, the relevant machinability aspects and the material
properties were presented.The alternating tool load, especially the peaks of the
cutting force, have been identified as responsible for both tool breakage and
increased wear due to a relative movement between insert and work-piece. A 3D-
FEM simulation model of the external longitudinal turning process was developed
to investigate the effects of a variation in tool geometry on the alternating tool
load. By using the presented model, an optimized insert geometry with an
increased tool life was developed, which was validated in empirical cutting tests
using the optimized tool geometry. Tool life was increased by 70 % in dry turning
and by 100% in wet conditions. Furthermore, no tool breakage was observed by
using the optimized tool.

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10. Experimental Determination of Machining Responses in
Machining Austempered Ductile Iron (Adi).
Author: Kumar K.M, Hariharan P B.

Year:2013
This experiment was conducted to find the influence of the peak current, pulse on
time, pulse off time, tool geometry and austempering temperature on the EDM
performance characteristics of ADI material with copper electrode. It was also
tried to formulate a mathematical model for the responses such as MRR, TWR,
Surface Roughness (SR) and taper angle (DVEE). The conclusions from the
analysis of these experimental results can bespecified as follows:
1. Based on the experimental values, the current and pulse off time are the most
significant and critical
process parameters that affect all the responses, except MRR and DVEE.
2. The MRR and TWR increases with increasing current and pulse on time, but
the surface roughness and DVEE inversely affect by increasing these two
parameters.
3. Tool geometry does not have any reasonable influences in all the responses.
However the DVEE increasing with increase the tool cross section area.
4. Austempering temperature influences only in surface roughness of the material.
It was found that inversely proportionate with surface roughness.

11.Effect of Machining Environment on Turning Performance of

Austempered Ductile Iron.
Author: Sagar Namdev Sakharkara, Raju S. Pawadeb.
Year: 2018
In this study numbers of experimental runs were conducted to investigate the
effect of MQL, dry and flood coolant environment in cast ADI turning, and
following results are concluded.
i..MQL and flood coolant removes heat and lubricate machining region. MQL
effectively lubricated surface due to capillary action of aerosols and flood coolant
given more cooling effect due to bulk volume of coolant. Therefore, MQL

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provided good lubrication with small volume of lubricant which helped in
reducing pollution.
ii. Triple CVD coated tungsten carbide has shown less wear therefore it achieved
higher tool life. Main abrasion wear is found on tool flank in machining with dry,
MQL and flood environment and relatively it was less the dry and flood
environment.

iii. Cast ADI produced elemental thin chips due to shearing, segmentation and by
rapid contraction.

12. Tool-Chip Contact and Chip Formation in Dry Finish-

Machining of Austempered Ductile Iron.
Author: Kambuyi Katuku.
Year:2022
Despite the temperature rises in PDZs and SDZs, the shear flow stress of
structural ADI does not decrease there. Strain-rate effects on this shear flow stress
overpower their antagonist temperature influences drastically in PDZs and
gradually in SDZs. Accordingly, TC sliding-friction coefficient rises with the
mean TC homologous temperature. The following holds irrespective of the
selected cutting speed and nominal rake angle. For a set uncut-chip thickness, chip
formation is active between two ends. The first end is complete sticking friction. It
relates to minimum chip compression ratio and maximum mean TC compressive
stress (higher TC sliding-friction coefficient and temperature). The second end is
total sliding friction.

13.An Analysis of The Machinability of Astm Grades 2 and 3

Austempered Ductile Iron.
Author: Marcelo Vasconcelos de Carvalho, Davi Melo Montenegro,
Jefferson de Oliveira Gomes.
Year:2013
The microstructure of G2 ADI was found to be coarser than that of G3 ADI.
Material characterization showed that the tensile strength, yield strength and

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nodules count of the alloys agreed with the ASTM standards for G2 and G3 ADI.
However, elongation values found were 39% and 44% lower for G2 and G3,
respectively. XRD tests showed that the samples fabricated did not present a
sufficient amount of carbon content within the austenite phase to stabilize it,
meaning that stress-induced transformation from austenite to martensite could
have happened during machining. The quick-stop test on G2 revealed that,
contrary to other cast irons, in which the workpiece material fails ahead of the
tool, one is able to identify the shear plane angle when machining this alloy, due
to formation of

segmented chip, in which welding unites elemental parts. The chip thickness ratio
calculated was r = 0.6, a lower value than most steels, meaning that the material
does not deform as much as steel before shearing off.

14. Optimization of Surface Roughness and Tool Wear in Hard

Turning of Austempered Ductile Iron Using Taguchi Method.
Author: D. Manivel , R. Gandhinathan.
Year:2016
In this paper, Taguchi orthogonal array L18 was used. The optimal cutting
parameters were determined in the turning of austempered ductile iron (grade 3)
using cvd-coated carbide inserts under dry turning conditions the Taguchi method
was used. The confirmation experiments were used to validate the optimum
cutting parameters. Based on the anova and S/N ratio analysis, the following
conclusions can be made.According to results of anova analysis, the main
contributing factors affecting the surface roughness and tool wear were cutting
speed with a contribution of 49.1% and 50.2% respectively. The significant
contributions of the nose radius, feed rate and depth of cut on the surface
roughness were found to be 14.6%, 21.6% and 9.7% respectively and on tool wear
found to be 5%, 30.2% and 11.3% respectively. Based on the S/N ratio using
‘‘smaller is the better” approach, the optimum level of cutting parameters for
surface roughness r1v1f2d1 (i.e., Nose radius = 0.8 mm, cutting speed = 50
m/min, Feed rate = 0.08 mm/rev, and depth of cut 0.2 mm) and tool wear were
r2v2f3d2 (i.e., Nose radius = 0.4 mm, cutting speed = 100 m/min, Feed rate = 0.12

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mm/rev, and depth of cut 0.3 mm). The good surface finish was achieved in 0.8
mm noseradius and minimum tool wear achieved in 0.4 mm nose radius.

15.Machinability Evaluations of Austempered Ductileiron and

Cast Steel with Similar Mechanical Properties Under Eco-
Friendly Milling Conditions.
Author: Dogancan Eraslan , Ahmet Balc , Barıs‚ etin , Necati Ucak ,
Adem C¸
Year:2021

In this study, the effects of different cooling/lubrication conditions on cutting

forces, surface roughness, subsurface microstructure, tool wear, and chip
formation were experimentally investigated in milling austempered ductile iron
(ADI) and cast steel (CS). It was aimed to introduce determination and
comparison of the machinability of ADI to CS having similar mechanical
properties, i.e. could be treated as alternative material options in design period.
The key findings of the study are as follows:
Due to higher hardness and special ausferrite microstructure of ADI, higher
cutting forces and tool wear were observed in comparison to CS. Lesser tool wear
and cutting forces were obtained under dry conditions. Conventional cutting fluid
(CCF) conditions deteriorated the tool life for both ADI and CS due to the effect
of thermal cycling on cutting tools. This resulted the formation of thermal cracks
on cutting edges when machining ADI.

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Chapter 4
RESEARCH GAP
This section discusses in detail the limited information on machining of the various ADI
grades both from prior research academic studies and also from other available databases.
At the present time, limited comprehensive machining recommendations for the
commercial grades of ADI have been published. A great deal of interests from different
companies in the availability of this information also encourages research in this topic.
Studies of ADI during its early development in the 1990’s initially suggested that ADI
has very poor machinability after heat treatment. Because of the lack of knowledge on the
machinability of ADI, machine shops have tried to machine high hardness, high strength
ADI as if it were a steel or as-cast ductile iron and have encountered failure. Although
narrow machining studies of ADI have been conducted, the state-of-the-art knowledge on
machining ADI is still very scarce. Moncada et al. conducted early ADI machining
studies in 1998 and generated initial machining data for only selected grades of ADI
under very limited machining conditions, not allowing general standard machining
guidelines for ADI to be developed. One and a half decades later in 2012, Akdemir et al.
still shared the same belief that comprehensive machining guidelines for ADI grades have
not yet been established.
In specific, this research effort includes:
 Review of the available information and existing knowledge on machining of ADI
 Machining (turning) trials of ADI at different cutting parameters to collect
machining data, such as tool life, surface roughness and chip formation
 Analysis of the machining data to provide starting recommendations to machine
ADI based on machinability criteria (i.e. average tool life, minimum surface
roughness, etc.)
 Investigation of the possibility of using surface finish appearance and chips formed
as a rapid approach to determine whether a cutting parameter is “acceptable” or not.
 Characterization of the martensitic transformation on machined ADI surfaces to
propose a way to improve machinability of ADI.

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Chapter 5
OBJECTIVES
The primary purpose of conducting this research work on ADI machining is to understand
the tool chip contact and chip formation in machining of ADI. The experimental design
mainly focuses on tool chip contact and chip formation causes and its effects on
machining. The research aim is to investigate the new possibilities involved in machining
of Austempered Ductile Iron (ADI). During the machining of ADI, the microstructure is
rapidly changed from ausferrite to martensite due to high rate of plastic deformation and
heat or combination of both. Therefore, the key to the machinability of ADI is either to
machine despite the formation of martensite.that is use ultra-hard cutting tools and low
cutting speeds with elevated penetration (feed) rates; or to use different approaches to
minimise, or even completely eradicate, the production of martensite by not allowing
strain hardening to commence.
• To determine if it is possible to adopt an approach where the toughest grades of ADI can
be successfully machined.
• To generate data for the machinability community to enable the growth of ADI to
continue into new application bases currently not accessible due to the belief that it has
relatively poor machining characteristics.

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Chapter 6
METHODOLOGY
Procuring of material

Machining of material

Heat treatment at different temperature

Machining of heat treated material

Chip collection and morphology

Tool tip study

Calculate tool life

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Chapter 7

MACHINING AND MACHINABILITY

Typical machining operations namely face milling, turning and drilling are briefly described in
this section.

7.1 Typical Machining Operations

Machining processes are characteristically used to create the designed geometry,
dimensions and surface finish of components. Milling, turning and drilling are
considered to be the three most basic machining operations used to achieve these
objectives. The difference in these operations is in the process of chip formation.

Milling

A multipoint tool is typically used in the milling operations to produce flat surfaces
and various workpiece profiles. Ball nose end mills, thread mill cutters, taper,
dovetail, radius and chamfer mills can also be used to create profiles. Face milling
is commonly used to generate many flat surfaces.
Key face milling process variables are the peripheral cutting speed of the cutting
tool inserts V, the feed rate f, and the radial w and axial d depth of cut. In addition,
the effective cutting diameter D and the number of inserts n must also be
considered when characterizing face milling operations.

Turning

Turning is a rotational machining process which is performed on a lathe or a

turning center often using a single point tool to produce external profiles.

Turning variables are adjusted to meet the final surface finish and dimensional
accuracy requirements depending on the workpiece materials being machined, the
tool material and geometry, and the capability of machine tool. The influence of
turning variables on machinability (tool life, cutting forces and chip formation)
must be also taken into consideration. These primary variables are surface speed V
or rotational speed N of the workpiece, the feed rate f , and depth of cut d.

Dept. of Mechanical Engg., Dr.A.I.T. 2022-23

Experimental Study of Tool Chip Contact and Chip Formation in Machining of ADI

Drilling
Drilling is a machining process used for rough hole-making which can be done in
both machining and turning centers. Controlling the temperature in the tool–chip
interface is especially important in the drilling process. An effective distribution of
coolant must be achieved to minimize heat generation. Inadequate cooling during
drilling can deteriorate the workpiece and may result in premature failure of drills.
Another essential practice in drilling operations is assuring chip removal from the
hole during drilling without interfering with the surface of drilled holes. Thru-
spindle coolant systems can be used for both rapid chip and heat removal. Higher
material removal rates can be achieved when these drilling systems are used.
Key drilling process variables include the peripheral cutting speed of drill V, the
feed rate f, and the drill depth d. In addition to proper selection of drilling
parameters, the drill geometry and materials also play important role in successful
drilling. Also, a minimum drill length-to-diameter ratio is desirable to avoid flexing
during drilling which can cause hole dimensional inaccuracy or early catastrophic
failure of drills.

From all these available machining process we have selected turning process as our
main machining process and all the data we are considering is from the turning
process only.
7.1.1 Turning of ADI

A large number of studies have investigated the turning of ADI. However, only about
half of the studies were done using carbide cutting tools. Furthermore, many of the ADI
turning studies reported in the literature were conducted without coolants.as for now we
have completed one round of machining(turning) without any coolants or with dry cuts

We have attached the images of specimen or ADI before and after machining
process(turning).

Dept. of Mechanical Engg., Dr.A.I.T. 2022-23

Experimental Study of Tool Chip Contact and Chip Formation in Machining of ADI

Fig 7-1 ADI before machining(turning) process

Fig 7-2 ADI after machining(turning) process done

Dept. of Mechanical Engg., Dr.A.I.T. 2022-23

Experimental Study of Tool Chip Contact and Chip Formation in Machining of ADI

Chapter 8

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Dept. of Mechanical Engg., Dr.A.I.T. 2022-23