Study of machinability of high carbon high chromium steel using various cutting tool

2.  INTRODUCTION
 OBJECTIVE
 LITERATURE RIVIEW
 PLAN OF WORK
 PROGRESS
REFERENCES

3.  Machinability means “ease of machining”.
 Machinability of a work material depends mainly on five
factors –
Cutting Force
Cutting Zone
Temperature
Tool Life
Surface
Roughness
Chip
Formation

4.  Study the Machinability of high carbon high
chromium steel using various cutting tool and find
out the optimum value of process parameters (i.e.
cutting velocity, feed rate, depth of cut) for
i) Minimum surface roughness
ii) Minimum power consumption
 Study the morphology and phase transformation of
machined chips

5.  Coromant (1989) recommended the use of
mixed alumina or wisker reinforced alumina at
cutting speed of 80-90 m/min and feed rate of
0.1-0.25 mm/rev to machine HRC above 46.
 Raghavan (1985) performed face milling on hot
work tool steel AISI H13 (48-50 HRC) using
PCBN at cutting speed of 100-200 m/min, feed
rate of 0.1mm/tooth and 1mm depth of cut.

6.  Konig et al. (1990) published a work on drilling
of a range of ferrous alloys hardened to ~62 HRC
at a cutting speed of 200 m/min and a feed rate of
0.02 mm/rev by using a 34 mm diameter drill
equipped with two PCBN inserts.
 Chen et al. (1991) did rotary turning on hardened
plain carbon steel (50-55 HRC) using PCBN at a
range of cutting speed of 145-250 m/min, with a
feed rate of 0.11 mm/rev and a depth of cut of
0.05 mm.

7.  Camascu et al. (2005) did a comparative study on cutting
tool performance in end milling of AISI D3 cold work
tool steel hardened to 35 HRC
 Used coated carbide, coated cermets, alumina based
mixed ceramic and cubic boron nitride (CBN) cutting
tools
 Found that both CBN and TiCN mixed alumina ceramic
tools give high tool life, better surface finish.
 TiCN coated carbide exhibited the worst performance
 Concluded that TiAlN coated material is better than
TiCN coated material in machining of hardened tool
steels.

8.  Bhattacharya et al. (2009) was investigated the effect
of cutting parameters on surface finish and power
consumption during high speed machining of AISI
1045 steel using coated carbide tools.
 investigated the contribution and effects of cutting
speed, feed and depth of cut on three surface
roughness parameters ( 𝑅 𝑎 , 𝑅 𝑞 , 𝑅𝑡 ) and power
consumption
 found that cutting speed to be the most significant
parameter for the workpiece surface roughness
followed bu feed rate and depth of cut.
 The most optimal result for surface roughness were
observed when the cutting speed was set at 240
m/min and feed rate of 0.125 mm/rev

9.  Hamdan et al. (2012) was performed an experimental
studies to optimize the machining parameters to
reduces the cutting forces and surface roughness in
high speed milling of stainless steel using coated
carbide tool.
 Four different factors were taken which were
lubrication method, feed rate, cutting speed and
depth of cut at three different experimental levels .
 feed rate was found to be more significant followed
by cutting speed and depth of cut and the lubrication
modes was found statistically insignificant.

10.  Ding et al. (2010) was performed an experimental
investigation on the effects of cutting parameters on
cutting forces and surface roughness in hard milling
of AISI H13 (50−
+ 1 HRC) steel with coated carbide
tools.
 With four factors cutting speed(v), feed(f), radial
depth of cut(𝑎 𝑒), axial depth of cut (𝑎 𝑝) at four
levels orthogonal experiments has been employed.
 Found that the axial depth of cut and feed are two
dominant cutting parameters that affect the cutting
forces

11.  Zhang et al. (2009) did an experimental and
analytical analysis on chip morphology, phase
transformation, oxidation and their relationship in
finish hard milling of AISI H13 tool steel (50−
+ 1
HRC) with coated inserts.
 The chip morphology and phase transformation were
examined on a scanning electron microscope.
 It was showed that cutting speed and feed rate are
critical parameters affect the chip morphology and
the transition from continuous chip to saw tooth chip


12.  Saha et al. (2014) did an experimental study on
reduction of formation of burr in face milling of
45C8 steel
 This experimental work found out the condition to
suppress burr formation effectively during face
milling of 48C8 steel specimens in dry condition
 In this study in plane exit angle has been fixed at
120° and the exit edge bevel angles have been varied
from 0° to 45° at an interval of 5°.
 Results showed that at 15° exit edge bevel angle
cutting speed-feed condition tiny burr is formed

13.  Iyer et al. (2007) did a work on helical milling for
drilling of AISI D2 tool steel, which employed a
rotating end mill that traverses a helical trajectory to
generate a hole
 It was presented the proof-of-concept of helical
milling as an enabling process technology for
machining precision holes in fully hardened AISI D2
tool steel.
 Helical milling as the negative rake tool corresponds
to a robust process with an order of magnitude
improvement in tool life and facilates dry cutting that
represents significant cost savings and a substantial
benefit to the environment.

14.  Experiment will be performed at four levels with
three process parameters (i.e. Cutting velocity,
Feed rate, Depth of cut)
 Surface roughness and Power consumption will
be taken as Response.
 Response Surface Methodology (RSM) will used
to established the relationship between the
response and factor affecting the response.

15. SL NO. DIAMETER OF
THE CUTTER
(mm)
SPINDLE
SPEED
(revolution per
min)
CUTTING
SPEED
(mm/min)
FEED RATE
(mm/tooth)
DEPTH OF
CUT
(mm)
SURFACE
ROUGHNESS
POWER
CONSUMPTION
𝑅 𝑎 𝑅 𝑀𝑎𝑥 𝑅10𝑍
1
54
1000 169.64 0.08 1
2 2
3 0.12 1
4 2
5 1800 305.36 0.08 1
6 2
7 0.12 1
8 2
9 1400 237.50 0.10 1.5
10
11
12
13
14
15

16.  Literature Review is partially completed
 Purchase of work material (High carbon high
chromium steel) is completed
 CNC Programming for Machining of the work
material is on progress.

17.  Insert selection
 Composition Test of the work material
 Experimental work (It is pending as CNC Machine
tool is not in working condition at present)

18. The Thesis on “STUDY OF MACHINABILITY
OF HIGH CARBON HIGH CHROMIUM
STEEL USING VARIOUS CUTTING TOOL” is
on progress.

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25. THANK YOU