CAREER EPISODE A

TOPIC NAME
A.1 Introduction
This career episode was created as part of the project "Topic Name". The project as a part of
my Bachelor of Engineering in Mechanical Engineering was carried out at University Name
situated in the ……... The project was completed under the supervision of Mr._______ and
submitted to the Department of Mechanical Engineering. The project started on DATE and was
finished on DATE.
A.2 Background
A.2.1 Project Nature
New materials are being required across different industrial sectors such as aviation, space
technology with advancements in science and technology. These materials are manufactured
satisfying the required characteristics. These innovative materials machinings are not possible
with traditional tools. Traditional tool machining is time-consuming, costly, and the work tools
have a very short tool life. Thus, to enhance the machinability of these materials, decrease the
power consumption during the process, and enhance the tool life, an innovative modern
machining method is needed. Hot machining is one such method. In hot machining, the work
piece's temperature is increased to hundreds or even thousands of degrees above the
surrounding temperature. For heating, numerous heating methods are employed like plasma
arc heating, area heating using a torch, etc.
In this project, at 1st Nihard material was procured and its characteristics were studied. But
there were some defects which were not repaired so, the process of hot kind machining was
done on manganese steel. The experimental set-up for machining of the workpiece was
arranged with suitable heating arrangements. The Taguchi experiment was designed. Various
control parameters like feed, cutting speed, depth of cut, and temperature were selected to
investigate the behavior of the hot machining process. The statistical investigation was
executed and outcomes were interpreted. Tool wear and tool life were studied as the response
to the Taguchi experiment.
A.2.2 Objective
The aim of performing the objective was to investigate the hot machining process varying the
control parameters. The other objectives aimed to meet in the project were

 To determine the optimum values of feed, cutting speed, depth of cut, and
temperature.
 To reduce the power required for specific flank wear.
A.2.3 Nature of Work
I initiated the project with a background study on the project. I worked on the selection of the
material for experimentation considering its mechanical characteristics. I set up the
experimental tools for the testing of the hot KIND machining. I performed the experiment
considering the speed of cutting, depth of the cut, and the temperature for hot machining of
high manganese type steel. I also experimented to determine the tool life varying those
parameters. I prepared the graphs and analyzed the results of the experiment.

A.2.4 Organizational Chart

University
Name

Department of
Mechanical
Engineering

Head of
Department

Project
superrvisor

Project
Name
member

Figure 1: Organizational Chart

A.2.5 Responsibilities

 To perform the literature study on the basics and procedure of the experiment.
 To select the materials for machining based on their mechanical properties.
 To set up the experimental tool fitting the equipment for easy computation of results.
  To perform statistical analysis and interpretation of the result of the experiment using
Taguchi analysis.
 To perform the experiment considering the design of tool life as the response and
analyze the results.
A.3 Personal Engineering Work
A.3.1 Literature Review
I studied the development in the hot machining process during the past decades through
reviewing various journals and research papers. I read about the due process in hot machining,
its suitability, usage, and limitation. I researched the Taguchi method with its drawbacks. I read
about different control parameters during the hot machining using the Taguchi method. I
examined how various control factors affect the response of the hot machining process. I
studied various control factors such as speed, temperature, and depth of cut and the response
of the hot machining process such as tool life and tool wear. I reviewed the experimental set-up
for machining, heating arrangements and carbide insert to machine the workpiece. I learned
about various problems that may arise while experimenting so that the experiment can be
completed in time with a proper tackling approach.
A.3.2 Selection of material
I used Ni-Hard material for the experiment in our project. I procured the required material from
the local market. I observed some defects in the materials like non-uniform lateral dimension,
and the bend present in the workpiece which couldn’t be corrected by any means. I observed
the mechanical and chemical properties of the specimen. I found hardness 550-650, tensile
strength 55,000 psi, and pH 6-8 as the mechanical properties of the specimen. So, I carried out
our project by performing hot kind machining on required large manganese steel. I selected the
appropriate type of heating arrangement using area heating by torch. I adopted the lathe
available in our workshop to do hot machining with proper heating arrangements. I selected an
SNMG carbide insert to machine the workpiece.
A.3.3 Experimental Set-up
I fitted the workpiece that had to be the machine in the lathe between the headstock and the
tailstock of the lathe. I fitted the torch so that it could move along with the cutting tool. I
connected the torch to the LGP cylinder and an oxygen cylinder. I made the setup via an earlier
investigator. I adjusted the flow rate of oxygen and LPG gas and also adjusted the distance for
the torch nozzle with the help of the handle provided with the equipment. I set the
temperature on a temperature indication in such a way that when the temperature arrived, the
torch was moved automatically away via the required workpiece. I performed this via utilizing a
control system and also making use of the thermocouple principle. I used the controller system
to move the torch away from the workpiece. I used an SNMG carbide insert to machine the
workpiece.
A.3.4 Taguchi Experiment
I followed the following steps to perform the Taguchi experiment. First, the problem was
formulated as the outcome of the experiment was relied on a total understanding of the
problem's nature. Then, I identified the output characteristics of the experiment. I considered
the controlling factors such as cutting speed, feed, depth of the cut, and the temperature for
the hot machining of the material. I selected the level of factors and probable in interaction and
the degree of freedom linked with every factor and the consequence of interaction. In our
experiment, I considered four control factors with three levels in each factor. As per the Taguchi
technique, I selected the L9 Taguchi design. I employed an orthogonal array in place of factorial
design reducing the total number of experiments from 24 to 9 experiments. I prepared the
experiment and run the experiment with a suitable collection of data. I identified the factor of
control which reduced the variation via observing variation amount present in the form of
response. I found that repetition data transformation was created by Taguchi and
transformation was SNR i.e. Signal-to-noise ratio. I discovered 3 kinds of SNR which were lower
SNR, nominal, and higher SNR. I did the statistical analysis and interpretation of the result of the
experiment.
Table 1: Parameters details

A.3.5 Experimental observation

I used the controlling factors in our experiment as shown in the table below. I used tool wear as
the response in our study so the tool with the least wear was best. I selected SNR to Smaller the
Better quality. I obtained the Average SNR as shown in table 2. I picked 3 level design i.e. there
was the presence of separate worth for every factor of control.

I obtained the control factors' main effect plot. I repeated the procedure till the flank wear
reached 0.5mm. After reaching this value, I didn’t use a tool to process further. Then, I
calculated the life of the tool. I grinded the tool and continued for 9 experiments.
Table 2: Experimental Observation
 Table 3: Average Signal to Noise Ratio

Figure 2: Control factors major effect plot (FIGURE REQUIRED)

A.3.6 Design of tool life as the response

After viewing the experiment, I did another task i.e. I modeled the life of the tool. I considered
the life of the tool up to the time when the wear of the flank reached 0.4mm. I grinded the
workpiece properly before the experiment on the tool was started. I adjusted the factors such
as depth of cut, feed, cutting speed, and temperature to definite experiment values. I removed
the tool in a 3-minute interval and measured the flank wear. I measured it with the tool maker’s
microscope. I continued the process, till the wear reached 0.5mm. I developed the graph
between time and flank wear.
1st run:
I took Cutting depth as 0.5 mm and temperature as 600 0 C while I set the feed as 0.05 mm/rev
and Cutting Speed as 175. Then, I observed tool wear against time.
I calculated the cutting force and found the average power required as 24.67 W. I computed the
cutting force as 77.41N. I analyzed the graph and found Tool life as about 40 minutes. I then
continued for the 2nd run doubling the depth of cut and feed as 1mm and 0.1mm/rev
respectively while reducing the temperature to 400 degrees. I found the average cutting force
to be 78.35N. Analyzing the graph, I found the tool life to be 32 minutes. I carried the next
seven-run as specification mentioned in the following tables and found the respective cutting
force and tool life from the graph. By analyzing the graph of cutting force vs. the run, I noticed
the reduction in cutting force as the number of runs progressed. I found the optimum value of
operation from the 1st run. I concluded that increasing the temperature could be the factor to
reduce the power used for machining and enhance the tool life. Analyzing all the results
employing the Taguchi statistical analysis I found the optimum result obtained was power
efficient as well as increased the tool life by about 15%.
Table 4: Tool wear vs. Time

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Table 5: Control Parameters and results

 Figure 3: Flank wear vs time (FIGURE REQUIRED)

Figure 4: Tool wear vs time (FIGURE REQUIRED)

Figure 5: Time vs Tool wear (FIGURE REQUIRED)

A.3.7 Problem and Solution

I faced a problem while machining the manganese workpiece by hot machine. I observed that
the wear of the tool was very high resulting in low tool life. This was against the objective of the
project. I discussed the problem among our colleagues. We tried to explore what may be the
cause of the problem and the right way to increase the tool life. I took advice from my
supervisor about the right way to solve the issue. I was advised that the feed speed was very
high. I had used the feed speed in the range of 2-4 mm/s which was very high for our
experimentation, resulting in rapid wear of the tool piece. I modified the feed by decreasing the
range of feed from 2-4mm/s to 0.05-0.1 mm/s. With the decrement in feed speed, I observed
gain in tool life. I observed the tool life in the range of 35-45 min, which was good for our
experiment.
A.3.8 Creative Works
For our experiment, I used the feed in the range of 0.05 mm/s to 0.15mm/s. And also, I set the
parameters to make the operation smooth. I smoothened the machining operation by
increasing the temperature to 600 degrees Celsius. I also ran the experiment for 9 numbers of
times to find the optimum combination of parameters.
A.3.9 Team Coordination
I collaborated with a small group of people on the project. I led the team while working under
the supervision of my supervisor. I started the project by setting up a meeting with the project
partner and mentor. To make things easier, I divided the assignment among the team
members. I kept a careful eye on the project and monitored the task of teammates. I organized
a meeting when there was a need for any ideas or innovation. I asked for the help of the seniors
and teacher whenever the problem bothered us. I briefed the mentor about the specifics of the
project. I made certain that the project's task was completed on time. I assisted in deriving the
results and preparing the graphs of the project.
A.3.10 Ethics
I performed the project considering the standards developed by the Mechanical Engineering
Society. I also followed the rules developed by the department. Specifically, I followed ISO
25.080.10 standard for the usage of the Lathe during the experiment.
A.4 Summary
The objectives set at the beginning of the project were achieved successfully. The experimental
set-up for machining of the workpiece was arranged with suitable heating arrangements.
Various control parameters like feed, cutting speed, depth of cut, and temperature were
selected to investigate the behavior of the hot machining process. It was obtained that
temperature plays a huge part in reducing the power and enhancing the tool life.
The project helped me in gaining practical insights into theories learned. I worked with the
team leading them during the project. It helped me in gaining leadership ability. I also found
techniques to manage the time and team. I also developed an issue-solving ability.