PERFORMANCE ANALYSIS ON HARD TURNING

PROJECT MEMBERS

GVK DATH 11189D021

PROJECT GUIDE
G.MAHESH REDDY 11189D026
Dr. A.TAMILARASAN
I.SHANKAR ADITYA 11189D029
Assistant Professor
I.RAJ KUMAR 11189D030

V.CHARAN KUMAR 11189D082

 INTRODUCTION:
Hard turning is defined as the process of single point cutting of part
pieces that have hardness over 45Rc
Turning of hardened metals has been popular in recent years as an
economic way of generating a high quality finish.
Hard turning can machine complex work pieces in one step.
Hard turning produces finishes approaching grinding quality.
 
It is less time consuming,more flexible,and economical.
Although grinding is the typical finishing process employed in industry,in
many cases hard turning is the better option for internal and external
finishing.
 HARD TURNING LIMITATIONS
•TOOLING:
When considering the tooling material,its important to understand the applications
and critical attributes such as size and finish requirements.

The typical brazed tip CBN insert has a cost structure 3-4 times that of carbide.

Ceremaic,on the other hand,has a cost structure more similar to carbide but could not
be
Used for applications which had a tolerance range smaller than ,parts requiring a
greater
Accuracy in logically use CBN.

Ceremaic does not perform well in the presence of high thermal shocks,so it is not
generally a ggod candidate for coolant cutting.

Tool rigidity,tool placement,cutting tool geometry…….

 WHITE LAYER FORMATION:
The infamous white layer can rear its ugly heading both turning and grinding
operations
Hard turned surfaces frequently exprince white layer formation,which appear as a
white layer at the surface at the material under metallographic examination.
This layer depth can very greatly but for general discussions it is in the area of 1
micrometer thick .

White layer can be caused by either:

1.Severe plastic deformation that causes rapid grain refinement or
2.Phase transformations as a result of rappid heating and quenching
The following process parameters were selected based on the literature review as
follows:
Developed experiment design:
In the present work, experiments were planned
using the BBD of RSM to obtain a quadratic
model consisting of 17 trials .

Study Type : Response Surface

Runs : 17
Initial Design : Box-Behnken
Design Model : Quadratic
 MACHINE PROCESS CAPIBILITY:
RIGIDITY is critical for successful hard turning:the rigidity of
tooling,workholding,and the machine tool itself are all crucial elements that will affect
your ability to successfully hard turn.
HARD TURNING IS A TECHNOLOGY-DRIVEN PROCESS,dependent upon
• Machine techonology
• Process technology
• Materials and tooling techonology
• Work holding techonology
 JOHNSON-COOK MATERIAL MODEL:
A review study of material parameters of Johnson-Cook constitutive
and failure model (Johnson and Cook 1983, 1985) for some regularly
used aluminium alloys acknowledges that various researchers have
obtained different parameters for the same alloy. Therefore, it is very
important for researchers working in crucial areas to be selfgoverning
in the calibration of dynamic material models
 DETERMINATION OF PARAMETER A:

Performed a tensile test as per ASTM E8M standard on a Universal Testing Machine (UTM) at room temperature (25°C) and at a
reference strain rate (10-3 s-1). Parameter ‘A’ is the yield strength of the material, that can be found out by direct observation of the
stress-strain curve for materials showing yield point phenomenon and by 0.2% strain offset method.
 Determination of strain hardening parameters B and n:
If a tensile test is conducted at room temperature and 10-3 s-1 strain rate, then both the
second and third bracket of equation (1) simplifies to unity and gets reduced to the
following form:

On excluding the elastic part of the stress-straincurve and plotting (σ – A) and plastic strain on a
log-log plot. The slope of this curve represents the strain hardening exponent(n)and
the Y-intercept of the curve provides the strainhardening coefficient (B)
 Determination of strain rate sensitivity parameter C :

Stress –strain curves at varying strain rates are needed at room temperature. Strain rates from 10-4 to 10-1 s-1 can be obtainedusing a conventional UTM by
altering the cross-head speeds. One datum point from each of these stress-strain curves is chosen. This datum point resembles to the value of flow stress at a
constant plastic strain before the onset of necking. Since all the experiments are performed at room temperature, the third bracket of equation(1) simplifies to
unity and it gets reduced to the following form:
The reference strain rate ( o) is equal to 10-3 s-1. The term in first bracket of equation
(5)corresponds to the quasi-static flow stress at the reference strain rate. Let this flow
stress be represented as o.Therefore, equation (5) can be rewritten as:

Now in the left hand term of the equation (6) is plotted against logarithm of strain rate
multiplied by 10-3, the slope of this curve will represent the strain rate sensitivity
parameter.
 LITERATURE SURVEY:
Johnson and Cook (1983) suggested a simple model to describe the plastic behaviour
v
of metals under dynamic loading. The model defines the equivalent flow stress as a
function of strain, strain rate, and temperature.

where A is Yield stress,Bis Hardening modulus, Cis Strain rate coefficient, n Hardening
exponent and m is thermal softening parameter. These are to be determined
experimentally.eq is equivalent plastic strain, *Eq is the ratio of equivalent plastic
strain rate to a reference plastic strain rate. T* Is the homologous temperature and is
defined as
where T is the current temperature of thematerial, Tm is the melting
temperature of material and Tr is room temperature. The first, second
and third set of brackets in equation (1) picture the effect of isotropic
strain hardening, strain rate hardening and thermal softening
sequentially in an uncoupled manner.

Dislocation dynamics based material models like ZerilliArmstrong model

(1987) and Mechanical Threshold Stress model (Follansbee and Cocks
1988) have been introduced to judge linked nature of strain rate and
thermal sensitivity but they have not been able to overtake Johnson-
Cook (J-C) model due to complexity in the calibration of constants.
 What is Simulation?

• A simulation is attempt to model a real –life or hypothetical

situation on a computer so that it can be studied to see how
the system works.
• By changing the varaibles in the simulation,prediction may
be made about the behaviour of the system.
• It is a tool to virtually investigate the behaviour of the
system under study.
 Overview of DEFORM:
• Deform is finite element method(FEM) based process simulation
system or hypothetical situation on a computer so that it can be used
to see how the system works.
• Unlike general purpose FEM codes, DEFORM is tailored for
deformation modelling.A user friendly graphical user interface
provides easy data preparation and analysis so engineers can focus on
forming, not on leaving a cumbersome computer system.
 Advantages:

• Study the behaviour of a system without building it.

• Results are accurate in general,compared to analytical
model.
• Helps to find out unexcepted phenomenon, behaviour of
the system.
• Easy to perform “WHAT-IF” analysis.
 Disadvantages:
• Expensive to build a simulation model.
• Expensive to conduct simulation.
• Sometimes it is difficult to interpret the simulation result.
• It is costly to buy.
THANK YOU