mech ppt

1. Batch No: 03
Name of the Guide: Prof. NAGRAJ PATIL
Students name and USN
1.JAYASIMHA YADAV R.A [15BT6ME014]
2.MOHANTHI SATHYA .N [15BT6ME021]
3.SRIKANTH.G [15BT6ME040]
4.SURAJ.K [15BT6ME041]
Project Phase - III
“PERFORMANCE EVALUATION OF COATED AND
UNCOATED TUNGSTEN CARBIDE INSERT IN TURNING
AISI304”

2. STATEMENT OF THE PROBLEM
1. To study the performance or effectiveness of CNMG
grade cemented carbide insert in dry machining of ASIS
304 stainless steel.
2. To study the influence of cutting speed on average flank
wear for different duration of machining at constant feed
and depth of cut
3. To study the effect of cutting speed on various chip
characteristics during machining of austenitic stainless
steel.

3. WHY THIS PROJECT?
The major challenges while machining are expressed in high
adhesion affinity up to high cutting speed ranges, high thermal
loads as well as in a hardening of the material. Further the high
toughness leads to an unpropitious chip breakage Previous
researchers has not worked more detailed on this study. In
many industries machining of AISI304 is challenging , because
of their composition.

4. 1.Mass density:-7850kg/m³ Youngs modulus:-206Gpa Poissions ratio:-
0.3
2.Yields stress:-318Mpa Rupture stress:-335mpa Strength coefficient:-
880.
3.To make machining process easier this project has been choosen.
C-0.16% Al-0.07% Si-0.168% Mn-0.18% P-0.025% Cu-0.09%Fe-
Balance.
The physical properties are:-
Density:-7833kg/m Heat capacity:-650J/kg/k Laser wavelength:-
7833µm Speed of sound:-600m/s Melting temperature:-1500ºC
Boiling temperature:-2750ºC
MECHANICAL PROPERTIES

5. LITERATURE GAP
Considerable research and development efforts are directed worldwide
towards improving the machining operations to ensure efficient and
economic machining of austenitic stainless steels by proper understanding
of the behavior of the exotic material austenitic stainless steels during
machining.
However, difficulties in machining of austenitic stainless steels remained
unchanged.
An effective approach is still not available. Also machining of AISI 304
austenitic stainless steel using TiAlN coated tool technique is not reported.
Considering all the above facts the present work aims to study the
influence of different machining parameters on the machinability
characteristics using coating and uncoated insert interms of TOOL WEAR,
SURFACE ROUGHNESS, CUTTING TEMPERATURE.

6. PROJECT EXCECUTION METHOD
The machining were carried out on LATHE machine
For machining:-
Work-piece material:- AISI 304 steel
Inserts used:- coated carbide insert CNMG
Cutting speed (rpm):-285, 460, 725.
Feed:- 0.5 mm
Depth of cut (mm):-0.5mm
Environment:-Dry
K-Type thermocouple
Work piece
Fig 1: machining setup on lathe machine

7. PROJECT EXCECUTION METHOD
In the phase of work, tool life test is be carried out using three different
cutting speed, i.e. 285,460 and 725rpm with constant feed of 0.5m/rev
and constant depth of cut of 0.5 mm at dry environmental conditions.
First the machining was done at a speed of 285rpm with a feed of
0.5m/rev and depth of cut being 0.5 mm under dry environment
condition, for a particular time duration then for particular time
intervals temperatures were noted down the carbide insert that is the
cutting tool was observed under the digital micro-scope and the
photographs of the required surfaces were taken. This way the
progression of tool wear with machining duration for different cutting
speeds is studied for all the sides of the tool and at different cutting
speeds and the required testings were done.

8. MACHINING PROCESS:-
Tool Holder
PCLNR2525M12
AISI 304
(work piece)
Fig 2: machining of ASIS 304 stainless steel.

9. INNOVATION OF THE PROJECT
Austenitic stainless steel is a very hard material which is very
tough to machine in industries, they face a major problem due
to this property of the steel .
The tool life of the cutting tool is highly reduced because of
these hard materials.
The project involves calculation of tool wear at various
experimental parameters and to know how to reduce the
various tool wear using carbide inserts

10. The below Table-01 shows the different temperatures obtained at
different time intervals when coated inserts are used
Table-01:-
Cutting speed=725rpm depth of cut 0.5mm feed rate=0.02mm/rev
RESULTS AND DISSCUSSION

11. From the above Table-1 it is observed that as the
machining time increases the tool temperatures, chip
temperature, work piece temperature and the interface
temperature also increases. The maximum chip
temperature obtained during the machining period of 50
minutes is 120ºC, and it is also observed that when
compared to all other temperatures the chip temperature
is the maximum temperatures noted, hence the
maximum amount of heat is dissipated through the
chips obtained.

12. The below Table-02 shows the different temperatures obtained at
different time intervals when uncoated inserts are used
Table-02:-
Cutting speed=285rpm depth of cut=0.5 feed rate=0.07mm/rev

13. From the above Table -2it is observed that as the machining time
increases the tool temperatures, chip temperature, work piece
temperature and the interface temperature also increases. The
maximum chip temperature obtained during the machining period
of 35 minutes is 150ºC, and it is also observed that when
compared to all other temperatures the chip temperature is the
maximum temperatures noted, hence the maximum amount of
heat is dissipated through the chips obtained.
And from the above two tables 1and 2it can be observed that high
chip temperatures are obtained during machining with uncoated
inserts and it is also observed that the at a less machining time of
35 minutes a high temperature of 150⁰C is obtained in the case of
the uncoated insert where as during the machining of the coated
insert at a machining time of 50 minutes the chip temperature of
120ºC is obtained which is still less than the chip temperature
obtained during the machining using uncoated insert

14. The table-03 below shows the different chips obtained and different
surface roughness obtained at different working parameters
Table -03:-
The working parameters are as follows:-

15. Table -03 continued

17. SEM ANALYSIS:-
The SEM-scanning electron microscope testing was carried out in
CMTI-central manufacturing technology institute in Bangalore.
First the inserts were observed under scanning electron
microscope. Figures below shows the microstructure of uncoated
and CNMG coated inserts at low and high magnifications
respectively. These SEM images of uncoated and CNMG coated
inserts are clearly distinct.
SEM images of CNMG coated inserts:-
Fig.1:sem image of CNMG coated insert

18. From the above fig.1 the wear can clearly seen in the insert edge
cause due to machining
Fig.2(a) Fig.2(b)
The above figures 2(a) and 2(b) shows the microstructure images
of the CNMG coated inserts at different magnifications

19. Fig.3 Isometric view of the CNMG coated insert
The above figure 3 shows the isometric view of the CNMG coated
insert where a small portion of the insert is broken down during
machining.

20. SEM images of the uncoated insert:-
Fig.4(a) Fig.4(b)
The above figures 4(a) and 4(b) shows the microstructure images
of the uncoated inserts at different magnifications

21. Fig.5 Isometric view of the CNMG coated insert
The above figure 5 shows the isometric view of the uncoated insert

22. EDS ANALYSIS:-
The composition of the top surface of both the CNMG coated and
uncoated inserts were examined using energy dispersive spectroscopy
(EDS) as shown in below figures through X-ray. Which depict EDS
spectra along with chemical composition demonstrated that some
change in composition took place on the surface of the coated inserts.
The cobalt densification is less compared to the coated insert .Notable
changes include increase in concentration of Co and C on the top
surface of coated inserts. This shows that redistribution and
densification of Co took place on the top surface of coated inserts.
Increase in C percentage may be attributed to the formation of η
phase carbides. The increase in binder phase might be helpful in
enhancing the bonding strength of WC particle.

23. EDS result of CNMG coated insert:-
Fig 6:EDS result of coated insert.

24. The composition of the CNMG coated insert is given in the table-04
below:-
Table-04

25. EDS result of uncoated insert
Fig7: EDS result of uncoated insert.

26. The composition of the uncoated insert is given in the table-05 below:-
Table-05:-

27. The below Table -06 shows the different wears obtained on the cutting
tool at different time durations at Cutting speed (rpm):-285
Feed:- 0.5 mm Depth of cut (mm):-0.5mm

28. Fig 8:Effect of cutting speed at 285rpm
and machining duration on average flank
wear
Fig 9:Effect of cutting speed at 460rpm
and machining duration on average flank
wear
Fig 10:Effect of cutting speed at 725rpm
and machining duration on average flank
wear

29. VICKERS MICRO-HARDNESS:-
Hardness is one of the important mechanical characteristics and
results from different micro-structural and phase change of a
material. Therefore, the influence of CNMG coating was studied
on the Vickers hardness of ISO P30 cemented carbide inserts
and the results are as given below
Coated insert hardness:-2319HV0.3
Uncoated insert hardness:- 1930 HV1
Fig11 :bar graph showing the hardness of the coated and
uncoated inserts.

30. CONCLUSIONS:-
1.The hardness of coated inserts was more than that of uncoated inserts.
2.Coated carbide inserts resulted in increasing of tool life for different
cutting speed during machining of AISI 304 grade austenitic stainless
steel.
3.Smooth and more regular wear pattern were observed for coated inserts.
4.Feed rate plays a significant role on the surface finish of AISI 304 SS
when machined with CNMG coated insert.
5.As the cutting speed increased average flank wear also increased for a
particular machining duration.
6.Coated carbide tools perform better than uncoated carbide tools as far as
cutting forces are concerned.
7.Results show that, the machining of hard materials at higher speeds is
improved by using coated tools.
8.Cutting speed also has important effect on various chip characteristics.
When cutting speed increased, chip thickness decreased.

31. INDUSTRIAL APPLICATIONS
APPLICATIONS OF AUSTENITIC STAINLESS STEEL 304:-
1. It is used for chemical processing equipment, for food, dairy, and
beverage industries, for heat exchangers, and for the milder
chemicals.
2. Used mostly in the pulp and paper industry. used in stacks which
contain scrubbers.
3. Sometime used in boat fitting .
4. Woven or welded screens are used for mining, quarrying and
water filtration.
5. Sometimes with thread fasteners and springs are also used.

32. 1. Laboratory benches and equipment.
2. Coastal architecture railing and trim.
3. Boat fitting.
4. Chemical containers including for transport.
5. Heat exchangers and thread fasteners.
APPLICATIONS OF THE CUTTING TOOL:-

33. EXPECTED REAL TIME APPLICATIONS
1.Machining problems can be overcome by using R&D in metal
cutting .
2.More machining is possible in less time.
3.Eliminates coolant purchase and disposal costs.
4.The machining process easy for cleaning and is non hazardous.

34. INDUVISUAL RESPONSIBALITY IN THE PROJECT
Students name: JAYASIMHA YADAV R.A
CONTRIBUTION TO THE PROJECT: literature survey and review
Students name: MOHANTHI SATHYA .N
CONTRIBUTION TO THE PROJECT: literature survey and review
Students name:SRIKANTH.G
CONTRIBUTION TO THE PROJECT: Machining
Students name: SURAJ.K
CONTRIBUTION TO THE PROJECT: Machining

35. FUTURE PLANS
The further plans on the project is to further study on
tool wear and the types of chips obtained during the
experiment at various parameters like:-
1. Cutting speeds.
2. Time durations .
3. Temperatures .
And also calculate the tool wear on all the four sides of
the insert and also to know the chip thickness ratios

36. REFERENCES
[1] Atul Kulkarni ,Vikas Sargade, Chittaranjan More,
“Machinability investigation of AISI 304 ASS using multi layer
AlTiN/TiAlN coated carbide inserts”,procedia manufacturing
20(2018),548-553.
[2] R.Suresh, S. Basavarajappa, V.N.Gaitonde, G.L.Samuel,
“machinability investigations on hardened AISI 4340 steel
using coated carbide inserts ”, Int. Journal of refactory metals
and hard materials. 33, 2012, 75-86.
[3] Swapnagandha .S. Wagh, Atul .P.Kulkarni ,Vikas. G. Sargade,
“Machinability studies of austenitic stainless steel (AISI304)
usimg PVD cathode arc evaporation (CAE) system deposited
AlCrN/TiAlN coated carbide inserts”, procedia engineering 64,
2013, 907-914.

37. [5] M.Anthony Xavior,”Experimental investigations on the
machinability of AISI 304, AISI 52100 and AISI D2 steel
materials”. Middle east jounal of scientific research 21(9) 1550-
1560, 2014.
[6] A.A.Khan , M.Y.Ali and M.M.Haque,” a new approach of
applying cryogenic cooling in turning AISI 304 stainless steel”.
IJME vol 5,2010,No.2,171-174.
[7] Amlana Panda, Ashok Kumar Sahoo ,Arun Kumar Rout,
Ramanuj Kumar , Rabin Kumar Das “Investigation of flank wear
in hard turning of AISI 52100 grade steel using multi layer coated
carbide and mixed ceramic inserts ” ,procedia manufacturing
20,2018,365-371.
[4] S.Saketi, J. Ostby, Mollsson, “Influence of tool surface
topography on the material transfer tendency and tool wear in
the turning of 360 L stainless steel”. Wear, 368-369,2016, 239-
252.