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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 10 | Oct 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1110 DESIGN AND FABRICATION OF SKIVING AND BURNISHING TOOL R. Shanmugam1, N. Mohan Raj2, S. Gopinath3, S. Santhosh4 1Assistant Professor, Dept. of Mechanical Engineering, Meenakshi Sundararajan Engineering College, Tamilnadu, India. 2,3,4UG Student, Dept. of Mechanical Engineering, Meenakshi Sundararajan Engineering College, Tamilnadu, India. ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Skiving machines cut material in slices. This is similar to the procedure of cutting or laminating leather and laminates. The process is employed rather than rolling the material to shape when the material is not to be work hardened, or must not shed metal later which generally occur in cold rolling processes. Tighter tolerance can be achieved with the help of skiving. Generally, plain cutting tool is used while machining on a lathe. Skiving usually precedes burnishing. It is carried out in automatic lathes. Burnishing is a finishing operation, by which surface finish dimensional accuracy, work hardening can be improved, without the removal of metal. Mostly, ductile or malleable material can be burnished. This is a metal forming process. Key Words: Skiving, rolling, tolerance, burnishing, hardening. 1. INTRODUCTION The skiving are often applied to a wide range of applications and materials. In leather, skiving knives used to trim the thickness of the leather, usually around theedges,tothinthe material and create it easier to work with. In metal working, skiving used to take away a thin dimension of material or to cut thin slices in an existing material, such as heat sinks where a large amount of surface area is required relative to the volume of the piece of metal. Skiving are also used to gear cutting, where internal gears are skived with a rotary cutter (rather than shaped or broached) in a process analogous to the hobbing of external gears. There are many forms of burnishing processes. The common methods are roller burnishing and ball burnishing. In each case, a burnishing tool runs against the work piece and plastically deforms its surface. In some instances of the latter case it rubs, in the former it generally rotatesandrolls. The work piece may be at anambienttemperature,orheated to reduce the forces and wear on the tool. The tool is hardened and coated with special materials toextenditslife. 2. LITERATURE REVIEW From the papers “Combination Skiving and Burnishing for cylinder Bores “ and “ Tool and manufacturing engineers handbook” by the authors Derek Korn and Backerjian, the basic principle and the working of burnishing process has been understood and the burnishing process on a lathe has been implemented using roller burnisher. The selection of materials for the tool was referred from the Journal Manufacture and Materials - Materials for Cutting Tools by Dr David J Griev. The working and operations of automatic lathe has been studied from the papers “Textbook of ElementsofMechanical Engineering” by Murthy, S. Trymbaka and "Hints & Tips for Using a Lathe" by George Wilson. The fabrication and specification of the tool was referred from “Production Technology” by HMT tools. 3. WORKING OF SKIVING AND BURNISHING 3.1 SKIVING ON A LATHE Shafts can be skived with a HSS skiving tool with zero back rake or rake angle and 12.5˚ front clearance. Theskivingtool is placed at the bottom of the work piece and the shaft is rotated in the reverse direction for better removal of the material. No coolant is used while skiving since very little amount of heat is generated. The cutting speed depends on the material of the work piece and it varies from 300-700 rpm. Tool material: High Speed Steel. Fig -1: SKIVING ON A LATHE 3.2 BURNISHING ON A LATHE Roller burnishing is used for finishing with the help of a lathe. Metals that work must be at lower hardness. The depth of surface hardness by roller burnishing ranges from 0.1 to 0.7 mm.
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 10 | Oct 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1111 The quality of the obtained surface finish in roller burnishing depends on the work piece hardness, ductility of the work piece and the material of the burnishing tool. Hardness of the work piece must belowerthanthetool.High hardness work piece can also be rolled, but the tool life becomes shorter. Fig -2: BURNISHING ON A LATHE 4. MATERIAL SELECTION Table -1: TOOL AND MATERIAL TOOL MATERIAL SKIVING HSS M42 BURNISHING ROLLER HSS D2 BURNISHING BODY EN8 CARBON STEEL 4.1 M42 SUPER HIGH SPEED STEEL M42 super high speed steel is a cobalthighspeedsteel witha composition designed for high hardness and superior hot hardness. These properties make the steel an excellent choice for machining high-strength andpre-hardenedsteels, high-hardness alloys, and the difficult-to-machine, nonferrous super alloys used in the aerospace, oil, and power generation industries. M42 exhibits good wear resistance by virtue of heat-treated hardness (68 - 70 HRC), and the high cobalt content imparts the hot hardness. Assuch, the cutting edges on toolsmadeup of M42 super high speed steel are sharp and hard in heavy- duty and high-production cutting applications. Chart -1: PROPERTIES OF M42 HSS 4.2 D2 Super High Speed Steel D2 alloy Steel is a high-carbon, high-chromium, air- hardening tool steel that characterized by a relatively attainable hardness and diverse chromium-rich alloy carbides in the microstructure. These carbides offer good resistance to wear from sliding contact. Although other steels with improved toughness or improved wear resistance are available, D2 provides an effective combination of wear resistance and toughness, tool performance, price, and a widevariety ofproductforms.Also available as an Electro-Slag-Remelted (ESR) product. The remelting method improves homogeneity, refinement of carbide size,and the associated enhancementsinmechanical and fatigue properties. Chart -2: PROPERTIES OF D2 HSS 4.3 EN8 CARBON STEEL EN8 is medium steel usually being untreated on supply. EN8 has good tensile strength and is often used in applications such as: shafts, gears, stressedpins,studs,bolts, keys etc.EN8 is a very popular grade and is readily machinable in any condition. It is further surface-hardened to supply materials with enhanced resistance of wear, typically within the range of 50-55 HRC through induction processes. It is also availableinfree- machining versions, EN8DM and EN8M (212A42). 5. TOOL DESIGN 2D Drawing is done in AutoCad software and 3D Modeling is done in Creo parametric software.
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 10 | Oct 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1112 5.1 SKIVING TOOL Fig -3: 2D AND 3D MODEL OF SKIVING TOOL 5.2 BURNISHING TOOL Fig -4: 2D AND 3D MODEL OF BURNISHING TOOL 6. DESIGN CALCULATION Cutting speed, v = mm/min D = Diameter of the workpiece (mm) N = Spindle speed (r.p.m) v = 3.14*18*300/1000 = 16.96 mm/min The cutting force of the tool is given by the formula: F = KS*f*d*v where, P = Cutting force in kgf Ks = Specific cutting force of the material in kgf/mm2 (63 for Aluminium) f = rate of feed (mm/s) d = depth of cut (mm) v = cutting speed (mm/min) F = 260 x .06 x .1 x 16.96 F = 26.45 kgf 7. FABRICATION OF THE TOOLS 7.1 SKIVING TOOL Using tool and cutter grinder CNC , the metal block made of M42 HSS (152.40*19.05*12.7)is cut by an angle of 12.5˚,so that the angle at the edge is reduced to 77.5˚.Hence,the required specification of the tool is obtained using the tool and cutter grinder CNC. 7.2 BURNISHING TOOL The cylindrical bar made of EN8 Carbon Steel was step turned with two different diameters onaconventionalLathe. The specimen is turned to 9 mm as per the required dimension for the roller. The Grinding process was used to shapeandsharpentheHSS tool to be used in the cutting process. It also resharpen the tool when it gets blunt and thus allows the tool to be reused to a particular extent. Hardening is done to have a higher resistance to plastic deformation. The hardness of the material is increased to about 48-50 HRC. Polishing and buffing are finishing processes used for smoothing surfaces of workpiece using an abrasive and a work wheel. Milling used for machining parts to precise sizes andshapes. The burnishing tool body is milled to the required dimensions. A metal pin passing through holes in two or more plates, to hold them together, is made with a head at one end and the other end being hammered into a head after insertion. The
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 10 | Oct 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 1113 body and head of the burnishing tool is riveted into a single body. 8. PHOTOGRAPH OF FABRICATED MODEL Fig -4: FABRICATED MODEL OF TOOLS (Skiving tool, Burnishing tool and workpiece being skived and burnished) 9. COST ESTIMATION Table -2: ESTIMATED COST CONTENTS COST RAW MATERIAL Rs 1600/- BURNISHING ROLLER Rs 1100/- BURNISHING BODY Rs 2700/- 10. CONCLUSION The tools are successfully designed and fabricated to perform skiving and burnishing efficientlyandeconomically on a lathe. The tool material of High Speed Steel was chosen for machining the mild steel workpiece.Thetool lifedepends on the work piece .hence for longer tool life can be obtained with lesser hardness material in case of both the processes .This project has proven to be advantageous to perform skiving and burnishing on a lathe. 11. FUTURE SCOPE The Design of the tool holder can be made to specificallysuit CNC Mills and easy removal of tool. The tool can bemadeout of Carbide Material to work with harder jobs. Gear skiving can be performed using CNC powermachineforformationof gears. Burnishing can be performed on complex workpieces using CNC machine. REFERENCES [1] "Combination Skiving and Burnishing for Cylinder Bores" by Derek Korn. [2] “A breakthrough in skiving” by Wepplemann E. [3] “Tool and manufacturing handbook” by Backerjian. [4] “Textbook of Elements of Mechanical Engineering” by Murthy, S. Trymbaka. BIOGRAPHIES R. Shanmugam was born in Tamilnadu, India in 1987. He did his masters in thermal power engineering and MBA. He is currently working as a faculty of Mechanical Engineering and placement coordinator in Meenakshi Sundararajan Engineering college. Previously,He had worked as a junior engineer in mtab Pvt Ltd, India. He is a member of SAE society, Quality Circle forum and human rights organization. N. Mohan Raj was born in Tamilnadu, India in 1999. He is currently pursuing undergraduate degree in Department of Mechanical Engineering, Meenakshi Sundararajan Engineering College. S. Gopinath was born in Tamilnadu, India in 1999. He is currently pursuing undergraduate degree in Department of Mechanical Engineering, Meenakshi Sundararajan Engineering College. S. Santhosh was born in Tamilnadu, India in 2000. He is currently pursuing undergraduate degree in Department of Mechanical Engineering, Meenakshi Sundararajan Engineering College. 2nd Author Photo
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