Statistical Modeling of Surface Roughness produced by Wet turning using solub...IDES Editor
Machining tests were carried out by turning En-
31steel alloy with tungsten carbide tools using soluble oilwater
mixture lubricant under dif ferent machining
conditions. First-order and second-order surface roughness
predicting models were developed by using the experimental
data by applying response surface methodology and factorial
design of experiments. The established equations show that
the feed rate is the main influencing factor on the surface
roughness followed by tool nose radius and depth of cut. It
increases with increase in the feed rate but decreases with
increase in the cutting velocity and tool nose radius,
respectively. The predicted surface roughness values of the
samples have been f ound to lie close to that of the
experimentally observed values. There is an improvement
in surface finish by 10% with wet machining as compared
to dry machining.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
Investigations on The Effects of Different Heat Transfer Coefficients in The ...IJRESJOURNAL
ABSTRACT: In the metal machining, the cutting fluid has become a tough problem in term of the health of works and environmental protection. The heat transfer coefficients of the water-based fluid, mineral oil and plant oil are distinct. An investigation focused on the effects of different heat transfer coefficients (h) on the cutting thickness compression ratio, chip formation, stress distribution and specific cutting energy is presented and discussed. In this study, three heat transfer coefficients have been simulated by Third WaveAdvantedge in machining AISI 1045 steel during different cutting speeds.It has been shown that the Mises stress and temperature are both affected by the heat transfer coefficient. When the h reaches higher, the Mises stress increases and the temperature shows the opposite trend. Also, the results can be found that the chip compression ratio decreases and shear angle increases when hrises. The relationship between specific cutting energy and heat transfer coefficients can be found in this paper.
Influence of various parameters of cryogenic treatment on performance of tun...vivatechijri
Cryogenic treatment is supplementary thermal treatment done after conventional hardening
process, wherein hardened material is further cooled till cryogenic temperatures which may range from -80°C
to -196°C. In the case of various grades of steel, the cryogenic treatment process has proved to have improved
mechanical properties significantly through conversion of retained austenite to martensite and refinement of
grain structure of steel. However, the effect of cryogenic treatment on high hardness material like tungsten
carbide is still in research and results are uncertain. Ongoing research have suggested that cryogenic treatment
may result into improvement of hardness and wear resistance of tungsten carbide tools which in turn may
improve tool life and efficiency of the cutting operation. But, the amount of improvement in properties majorly
depends of various parameters of cryogenic treatments. This paper deals with reviewing various parameters of
cryogenic treatment like cooling cooling rate, soaking temperature, soaking time, tempering temperature,
tempering time and its effect on performance of tungsten carbide tool
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
Purpose – This paper seeks to evaluate the influence of tellurium content on the machinability of the microalloyed pearlitic steel (DIN 38MnS6).
Two grades of steels were used, one with high (27 times greater) tellurium content and one with a low tellurium content. Machinability of the steel was
determined by the number of holes drilled by the tool before undergoing severe deformation. The drilling test matrix was prepared using a fractional
factorial design with five input variables studied at two levels (25-1). Other variables investigated include cutting speed (45 and 60 m/min), feed rate
(0.15 and 0.25 mm/rev), geometry of the twist drills and use of minimum quantity lubrication (MQL) at the flow rates of 30 and 100 ml/h. Statistical
analysis of the results revealed that composition of the work material was most influential on tool performance. Addition of tellurium to the steel
significantly improved machinability, increasing the number of drilled holes by over 100 per cent. The MQL flow rate was the least influential as increase
in the flow from 30 to 100 ml/h reduced drill life only by about 9 per cent.
Design/methodology/approach – The drilling tests were carried out in the vertical position, up-down, without pre-holes (full drilling). Cutting
speeds of 45 and 60 m/min and feed rates of 0.15 and 0.25 mm/rev were employed. Drills with two sharpening types were tested. Cutting fluid used
was vegetable based and applied using the MQL technique at flow rates of 30 and 100 ml/h. The rejection criterion adopted was severe deformation of
the drills and the number of machined holes was used to measure the machinability of the material.
Findings – Of all the variables investigated in this study, the least influential on drill performance is the MQL flow rate. Increase in the flow rate from
30 to 100 ml/h reduced drill performance by 9 per cent, contrary to expectation. This is a result of the cooling-lubricant action balance promoted by the
cutting fluid applied in low quantities (MQL). The most influential variable on drill performance is addition of Te to the work material which gave over
twofold (103 per cent) improvement in drill performance at the cutting conditions investigated. The Te particles act at the chip-tool interface, reducing
the work necessary to shear the material during chip formation. Increase in both the cutting speed and the feed rate both lowered drill performance
during machining due to associated increase in cutting temperature which tended to accelerate thermally related wear mechanisms.
Originality/value – This work was conducted to evaluate the machinability of a novel alloyed steel employed in the automobile industry. Drilling was
considered as most automobile components especially the engine block is designed with many holes which require drilling process.
Statistical Modeling of Surface Roughness produced by Wet turning using solub...IDES Editor
Machining tests were carried out by turning En-
31steel alloy with tungsten carbide tools using soluble oilwater
mixture lubricant under dif ferent machining
conditions. First-order and second-order surface roughness
predicting models were developed by using the experimental
data by applying response surface methodology and factorial
design of experiments. The established equations show that
the feed rate is the main influencing factor on the surface
roughness followed by tool nose radius and depth of cut. It
increases with increase in the feed rate but decreases with
increase in the cutting velocity and tool nose radius,
respectively. The predicted surface roughness values of the
samples have been f ound to lie close to that of the
experimentally observed values. There is an improvement
in surface finish by 10% with wet machining as compared
to dry machining.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
Investigations on The Effects of Different Heat Transfer Coefficients in The ...IJRESJOURNAL
ABSTRACT: In the metal machining, the cutting fluid has become a tough problem in term of the health of works and environmental protection. The heat transfer coefficients of the water-based fluid, mineral oil and plant oil are distinct. An investigation focused on the effects of different heat transfer coefficients (h) on the cutting thickness compression ratio, chip formation, stress distribution and specific cutting energy is presented and discussed. In this study, three heat transfer coefficients have been simulated by Third WaveAdvantedge in machining AISI 1045 steel during different cutting speeds.It has been shown that the Mises stress and temperature are both affected by the heat transfer coefficient. When the h reaches higher, the Mises stress increases and the temperature shows the opposite trend. Also, the results can be found that the chip compression ratio decreases and shear angle increases when hrises. The relationship between specific cutting energy and heat transfer coefficients can be found in this paper.
Influence of various parameters of cryogenic treatment on performance of tun...vivatechijri
Cryogenic treatment is supplementary thermal treatment done after conventional hardening
process, wherein hardened material is further cooled till cryogenic temperatures which may range from -80°C
to -196°C. In the case of various grades of steel, the cryogenic treatment process has proved to have improved
mechanical properties significantly through conversion of retained austenite to martensite and refinement of
grain structure of steel. However, the effect of cryogenic treatment on high hardness material like tungsten
carbide is still in research and results are uncertain. Ongoing research have suggested that cryogenic treatment
may result into improvement of hardness and wear resistance of tungsten carbide tools which in turn may
improve tool life and efficiency of the cutting operation. But, the amount of improvement in properties majorly
depends of various parameters of cryogenic treatments. This paper deals with reviewing various parameters of
cryogenic treatment like cooling cooling rate, soaking temperature, soaking time, tempering temperature,
tempering time and its effect on performance of tungsten carbide tool
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
Purpose – This paper seeks to evaluate the influence of tellurium content on the machinability of the microalloyed pearlitic steel (DIN 38MnS6).
Two grades of steels were used, one with high (27 times greater) tellurium content and one with a low tellurium content. Machinability of the steel was
determined by the number of holes drilled by the tool before undergoing severe deformation. The drilling test matrix was prepared using a fractional
factorial design with five input variables studied at two levels (25-1). Other variables investigated include cutting speed (45 and 60 m/min), feed rate
(0.15 and 0.25 mm/rev), geometry of the twist drills and use of minimum quantity lubrication (MQL) at the flow rates of 30 and 100 ml/h. Statistical
analysis of the results revealed that composition of the work material was most influential on tool performance. Addition of tellurium to the steel
significantly improved machinability, increasing the number of drilled holes by over 100 per cent. The MQL flow rate was the least influential as increase
in the flow from 30 to 100 ml/h reduced drill life only by about 9 per cent.
Design/methodology/approach – The drilling tests were carried out in the vertical position, up-down, without pre-holes (full drilling). Cutting
speeds of 45 and 60 m/min and feed rates of 0.15 and 0.25 mm/rev were employed. Drills with two sharpening types were tested. Cutting fluid used
was vegetable based and applied using the MQL technique at flow rates of 30 and 100 ml/h. The rejection criterion adopted was severe deformation of
the drills and the number of machined holes was used to measure the machinability of the material.
Findings – Of all the variables investigated in this study, the least influential on drill performance is the MQL flow rate. Increase in the flow rate from
30 to 100 ml/h reduced drill performance by 9 per cent, contrary to expectation. This is a result of the cooling-lubricant action balance promoted by the
cutting fluid applied in low quantities (MQL). The most influential variable on drill performance is addition of Te to the work material which gave over
twofold (103 per cent) improvement in drill performance at the cutting conditions investigated. The Te particles act at the chip-tool interface, reducing
the work necessary to shear the material during chip formation. Increase in both the cutting speed and the feed rate both lowered drill performance
during machining due to associated increase in cutting temperature which tended to accelerate thermally related wear mechanisms.
Originality/value – This work was conducted to evaluate the machinability of a novel alloyed steel employed in the automobile industry. Drilling was
considered as most automobile components especially the engine block is designed with many holes which require drilling process.
Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
roughness on the work piece, cutting forces developed, temperature developed at the tool
chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
Surface residual stresses in machined austenitic stainless steelLepuufu
Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate,
depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning
conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic
deformation of the surface layers of the workpiece.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
Reducing And Analysizing of Flow Accelerated Corrosion at Thermal Power Plant...IJERA Editor
The purpose of this study is to Reducing and Analysing of Flow Accelerated Corrosion in Thermal Plant Heat Recovery Steam Generators. All these studies have been performed in a new and 16 year-old established Combined Cycle Power Plants in Turkey. Corrosion cases have been investigated due to Mechanical Outage Reports at Power Plant in 2011-2015. Flow Accelerated Corrosion study has been based on specific zone related with Economizer Low Pressure connection pipings. It was issued a performance report. Results and lessons learnt from these studies will be used as a preventive action manner in all similar Plants
Effect of Process Parameters on Micro Hardness of Mild Steel Processed by Sur...IOSR Journals
Surface grinding process can be utilized to create flat shapes at a high production rate and low
cost.. In this investigation, indigenously designed set up were used for evaluating the surface grinding process
was established. An experimental investigation was carried out to study the effect of surface grinding process
parameters i.e. Inlet pressure of coolant, grinding wheel speed, work-piece speed, and nozzle angle on the micro
hardness of the mild steel specimen. In the present study Horizontal spindle and reciprocating table type
surface grinding machine fitted with test rig is used and cutting fluid is applied through the convergent nozzle to
throw the cutting fluids at the cutting zone. In order to evaluate the effect of selected process parameters, one
variable approach has been used in the present study. Plots of various Micro Hardness responses have been
used to determine the relationship between the output response and the input parameters. The value of
microhardness of grinded mild steel work-piece varies from 292.63 to 370.73 HV
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Performance evaluation of nano graphite inclusions in cutting fluids with mql...eSAT Journals
Abstract Liberation of heat and generation of friction associated with any machining operation ever pose a problem which not only reduce the tool life but also impair quality of the product. Cutting fluids have been the conventional choice to curtail friction and temperatures in machining because of its lubrication and cooling actions. However, considering health hazards posed by the conventional cutting fluids to health of the workers and ecology, the quest is towards identifying alternative strategies to the usual flood application. Selection and use of proper lubricant that can improve the overall cutting phenomena which is an important aspect in reducing the cutting forces and temperatures The present work studies the use of nano cutting fluids in MQL which is a minimal cutting fluid technique, for turning operation using HSS and cemented carbide tools. Development of nano materials by nanotechnology technique, dispersing them in the cutting fluid improve the effectiveness of the cutting fluid and hence nano graphite powder is selected of particle size 80 nm in varying proportions i.e. 0.0%, 0.1%, 0.3% and 0.5% by weight are mixed in water soluble oil and applied drop by drop. Experimentation is carried out at different flow rates like 5 ml/min 10 ml/min and 15 ml/min with nanoparticle suspended fluids along with dry machining, flood coolant machining under constant cutting conditions. Experimental results are very encouraging with much reduction in surface roughness, tool flank wear, temperatures and cutting forces is observed in fluids with nanoparticle inclusions. Different properties of the nanofluids are estimated through a series of standard tests. Keywords: Machining, nano Graphite, minimum quantity lubrication, cutting fluids.
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Literature review of increasing tool life of hot forging die by reducing wear Bhavesh Panchal
By various coating and deposition method tool life increases of hot forging die. There are 5 research paper from trusted and authorised sites. Review of that papers have been shown here.
Impact of varying the nozzle stand off distance on cutting temperature in t...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve ...Dr. Amarjeet Singh
A numerical simulation approach is proposed to predict the optimal parameter setting during high pressure die casting. The contribution from the optimal parameters, the temperature, showed more influence on the casting quality than the other parameters. This study’s outcome was beneficial for finding the solution for casting defects that occurs due to incorrect setting of process parameters in die casting. Thus, a combination of numerical optimisation techniques and casting simulation serves as a tool to improve the casting product quality in die casting industries. This paper aims to analyse and optimise critical parameters like injection pressure, molten metal temperature, holding time, and plunger velocity, contributing to the defects. In this research paper, an effort has been made to give optimal pressure, temperature, holding time, and plunger velocity parameters using ProCAST simulation software that uses finite element analysis technology. Numerical analysis for optimising the parameters by varying the temperature of molten metal, injection pressure, holding time, and plunger velocity, concerning solidification time at hot spots, is an essential parameter for studying the defect analysis in the simulated model.
Optimization of Metal Removal Rateon Cylindrical Grinding For Is 319 Brass Us...IJERA Editor
Cylindrical grinding is one of the most important metal cutting processes used extensively in the Metal finishing operations. Metal removal rate and surface finish are the important output responses in the production with respect to quantity and quality respectively. The objective of this paper is to arrive at the optimal grinding conditions that will maximize metal removal rate when grinding IS 319 brass. Empirical models were developed using design of experiments by Taguchi L9 Orthogonal Array and the adequacy of the developed model is tested with ANOVA.
Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
roughness on the work piece, cutting forces developed, temperature developed at the tool
chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
Surface residual stresses in machined austenitic stainless steelLepuufu
Surface residual stresses due to turning operations in AISI 304 type stainless steel were studied as a function of machining speed, feed rate,
depth of cut, and tool geometry and coating. Residual stress tensors were determined using X-ray diffraction technique. The effects of turning
conditions and tool on the residual stresses were discussed in terms of mechanically and thermally induced non-homogeneous plastic
deformation of the surface layers of the workpiece.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
Reducing And Analysizing of Flow Accelerated Corrosion at Thermal Power Plant...IJERA Editor
The purpose of this study is to Reducing and Analysing of Flow Accelerated Corrosion in Thermal Plant Heat Recovery Steam Generators. All these studies have been performed in a new and 16 year-old established Combined Cycle Power Plants in Turkey. Corrosion cases have been investigated due to Mechanical Outage Reports at Power Plant in 2011-2015. Flow Accelerated Corrosion study has been based on specific zone related with Economizer Low Pressure connection pipings. It was issued a performance report. Results and lessons learnt from these studies will be used as a preventive action manner in all similar Plants
Effect of Process Parameters on Micro Hardness of Mild Steel Processed by Sur...IOSR Journals
Surface grinding process can be utilized to create flat shapes at a high production rate and low
cost.. In this investigation, indigenously designed set up were used for evaluating the surface grinding process
was established. An experimental investigation was carried out to study the effect of surface grinding process
parameters i.e. Inlet pressure of coolant, grinding wheel speed, work-piece speed, and nozzle angle on the micro
hardness of the mild steel specimen. In the present study Horizontal spindle and reciprocating table type
surface grinding machine fitted with test rig is used and cutting fluid is applied through the convergent nozzle to
throw the cutting fluids at the cutting zone. In order to evaluate the effect of selected process parameters, one
variable approach has been used in the present study. Plots of various Micro Hardness responses have been
used to determine the relationship between the output response and the input parameters. The value of
microhardness of grinded mild steel work-piece varies from 292.63 to 370.73 HV
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Performance evaluation of nano graphite inclusions in cutting fluids with mql...eSAT Journals
Abstract Liberation of heat and generation of friction associated with any machining operation ever pose a problem which not only reduce the tool life but also impair quality of the product. Cutting fluids have been the conventional choice to curtail friction and temperatures in machining because of its lubrication and cooling actions. However, considering health hazards posed by the conventional cutting fluids to health of the workers and ecology, the quest is towards identifying alternative strategies to the usual flood application. Selection and use of proper lubricant that can improve the overall cutting phenomena which is an important aspect in reducing the cutting forces and temperatures The present work studies the use of nano cutting fluids in MQL which is a minimal cutting fluid technique, for turning operation using HSS and cemented carbide tools. Development of nano materials by nanotechnology technique, dispersing them in the cutting fluid improve the effectiveness of the cutting fluid and hence nano graphite powder is selected of particle size 80 nm in varying proportions i.e. 0.0%, 0.1%, 0.3% and 0.5% by weight are mixed in water soluble oil and applied drop by drop. Experimentation is carried out at different flow rates like 5 ml/min 10 ml/min and 15 ml/min with nanoparticle suspended fluids along with dry machining, flood coolant machining under constant cutting conditions. Experimental results are very encouraging with much reduction in surface roughness, tool flank wear, temperatures and cutting forces is observed in fluids with nanoparticle inclusions. Different properties of the nanofluids are estimated through a series of standard tests. Keywords: Machining, nano Graphite, minimum quantity lubrication, cutting fluids.
In this experimental study, an attempt is made to obtain optimum cutting parameters for turning
of mild steel on the basis of surface roughness and surface temperature. Optimization of cutting parameters is
very important to obtain a good machining quality of surface and to inhibit the increase of temperature.
Minimum Quantity Lubrication (MQL) has been introduced to avoid excessive use of cutting fluid. The
parameters considered here are cutting speed, feed and depth of cut. Optimal cutting parameters for each
performance measure were obtained employing Taguchi experimental method. To study the performance
characteristics in turning operation Analysis of Variance (ANOVA) was employed. It is found that cutting speed
and feed has significant effect on both surface roughness and temperature.
Literature review of increasing tool life of hot forging die by reducing wear Bhavesh Panchal
By various coating and deposition method tool life increases of hot forging die. There are 5 research paper from trusted and authorised sites. Review of that papers have been shown here.
Impact of varying the nozzle stand off distance on cutting temperature in t...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve ...Dr. Amarjeet Singh
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IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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हम आग्रह करते हैं कि जो भी सत्ता में आए, वह संविधान का पालन करे, उसकी रक्षा करे और उसे बनाए रखे।" प्रस्ताव में कुल तीन प्रमुख हस्तक्षेप और उनके तंत्र भी प्रस्तुत किए गए। पहला हस्तक्षेप स्वतंत्र मीडिया को प्रोत्साहित करके, वास्तविकता पर आधारित काउंटर नैरेटिव का निर्माण करके और सत्तारूढ़ सरकार द्वारा नियोजित मनोवैज्ञानिक हेरफेर की रणनीति का मुकाबला करके लोगों द्वारा निर्धारित कथा को बनाए रखना और उस पर कार्यकरना था।
1. G.U. Journal of Science
22(1): 21-32 (2009)
www.gujs.org
♠
Corresponding author, e-mail: rrshetty2@rediffmail.com
Experimental Studies on Turning of Discontinuously
Reinforced Aluminium Composites under Dry, Oil
Water Emulsion and Steam Lubricated Conditions Using
TAGUCHI’s Technique
Raviraj Shetty 1♠
, R. Pai1
, S.S.Rao 2
1
Manipal Institute of Technology, Department of Mechanical and Manufacturing Engineering, Karnataka, India
2
National Institute of Technology, Department of Mechanical Engineering, Karnataka, India
Received: 31.10.2007 Revised: 09.07.2008 Accepted: 0.3.12.2008
ABSTRACT
This paper reports on the experimental investigations carried out under dry, oil water emulsion and steam
lubricated conditions in turning of DRACs. The measured results were then collected and analyzed with the
help of the commercial software package MINITAB15. The experiments were planned on orthogonal arrays,
made with prefixed cutting parameters and different lubricated conditions. An analysis of variance (ANOVA)
was carried out to check the validity of the proposed parameters and also their percentage contributions. The
results of the tests show that with proper selection of the range of cutting parameters, it is possible to obtain
better performance under steam lubricated condition.
Key Words: DRACs, Cutting force, Cutting temperature, Design of experiments, ANOVA, Hystrix cristata.
1. INTRODUCTION
Discontinuously reinforced Aluminium composites
(DRACs) is one of the important composites among the
metal matrix composites, which have SiC particles in an
aluminium matrix; this is harder than tungsten carbide
(WC), which pose many problems in machining. When
DRACs are being chosen for high volume and machine-
intensive components, it is crucial that the
machinability of the materials be understood. The
machinability of DRACs has been investigated actively
worldwide since the 1980s, and most researchers have
found that polycrystalline diamond (PCD) or cubic
boron nitride tools can be used to machine DRACs
effectively. Driven by the high cost of these tools, it is
still desirable to optimize the cutting conditions, such as
the effect of cutting fluid, since there has been no
comprehensive study undertaken in this area.
A Discontinuously Reinforced Aluminium Composites
(DRACs) can be described as a material which is made
up of a continuous metallic phase (the matrix) into
which a second phase (or phases) has been artificially
introduced. Early DRACs had their application
confined to military and aerospace applications, their
extensive usage was hindered due to their high
production costs, limited production methods, and
restricted product forms [1].
Machining of Discontinuously reinforced Aluminium
composites (DRACs) presents a significant challenge to
the industry since a number of reinforcement materials
are significantly harder than the commonly used high
speed steel (HSS) tools and carbide tools [2]. The
reinforcement phase causes rapid abrasive tool wear;
thus the widespread usage of DRACs is considerably
impeded by their poor machinability and high
machining costs. Based on the available literature on
DRACs it is clear that the morphology, distribution and
volume fraction of the reinforcement phase, as well as
the matrix properties are all factors that affect the
overall cutting process [2-3], but as yet relatively few
published reports are related to the optimization of the
cutting process.
2. 22 G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao
The positive effect of the use of cutting fluids in metal
cutting was first reported in 1894 by F.Taylor, who
noticed that by applying large amounts of water in the
cutting area, the cutting speed could be increased up to
33% without reducing tool life. Since then, cutting
fluids have been developed resulting in an extensive
range of products covering most workpiece materials
and operations.
As research shows, the application of gases as cutting
fluids has been used since 1930s. [4,5] reported the
experimental results of carbon dioxide gas application
in machining. It was noticed that application of carbon
dioxide gas as coolants and lubricants reduced the
cutting force and obtained a higher tool life. [6–10] also
deeply studied application of oxygen gas as cutting
fluids in cutting process . [10] observed these results
were promising that the application of oxygen gas was
an effective agent to reduce contact length of tool–chip .
However, In the 1990s, [11-13] used water vapor as
coolants and lubricants in turning and milling operation.
The results showed water vapor lubrication in
comparison with liquid one ensures more uniform
cooling and the application of vaporous lubrication
allows increasing the carbide cutting tools lifetime
about 2–2.5 times in turning and 2–4 times in milling
carbon and stainless steels. In 2007 [14] used
pressurized steam jet approach in turning of
discontinuously reinforced aluminium composites. The
result showed the steam pressure as the dominant
parameter for surface roughness followed by feed. [15]
also carried out experimental investigations under dry,
oil water emulsion and steam lubricated conditions
using orthogonal array in turning of DRACs, he
concluded that the tool wear and surface roughness
were found to be lesser for steam cutting, where as
these two parameters showed much variation during oil
water emulsion and dry cutting. [16] used a pressurized
steam jet approach to tool wear minimization in cutting
of metal matrix composites by full factorial design of
experiments, he concluded that the effect of the
pressured steam jet plays a significant role on the tool
wear followed by tool inserts and depth of cut. Further,
fluid jet assisted machining as a highly effective method
for cutting of conventional materials has been well
explored [17–30], in which fluids, such as air, water or
steam, mainly act as transportation carriers carrying the
heat away from the cutting region, and the efficiency of
such a cooling method largely depends on the jet
pressure. Therefore, it is necessary to understand the
relationship among the various controllable parameters
and to identify the important parameters that influence
the quality of turning. Moreover, it is necessary to
optimize [31-33] the cutting parameters to obtain an
extended tool life and better productivity, which are
influenced by cutting force and cutting temperature.
Design of experiment [DOE] is a statistical-based
approach to analyze the influence of known process
variables over unknown process variables. The current
article investigates the influence of cutting parameters
and lubricating conditions on cutting force and cutting
temperature in turning of DRACs with Cubic boron
nitride inserts (CBN) KB-90 grade.
2. METHODOLOGY
2.1 Material
Al–SiC MMC workpiece specimens popularly known
as DRACs having aluminum alloy 6061 as the matrix
and containing 15 vol. % of silicon carbide particles of
mean diameter 25 m in the form of cylindrical bars of
length 120mm and diameter 40mm manufactured in
Vikram Sarbhai Space Centre (VSSC) Trivandrum by
stir casting process with pouring temperature 700-
710°C, stirring rate 195 rpm, extrusion at 457°C,
extrusion ratio 30:1, direct extrusion speed 6.1m/min to
produce Ø40mm cylindrical bars. The specimen were
solution treated for 2h at a temperature of 540oC in a
muffle furnace, temperatures were accurate to within
±2oC and quench delays in all cases were within 20s.
after solutionising, the samples were water quenched to
room temperature, and subsequently aged for six
different times to obtain samples with different Brinell
hardness number (BHN), out of which one samples
were selected, one with 94 BHN obtained at peakage
condition i.e 2h at 220oC respectively. Sample selected
were kept in a refrigerator right after the heat
treatments. Figure 1 shows the microstructure of
DRACs.
Figure 1. A microstructure of an DRACs (6061 Al/ 15%
SiC 25p).
2.2 Machining Test
The chemical composition of the specimen is given in
Table 1. Turning, as a machining process was selected.
The experimental study was carried out in PSG A141
lathe (2.2 KW) with different cutting speeds, feeds and
a constant depth of cut. The selected cutting tool was
cubic boron nitride insert KB-90 (ISO code), for
machining of DRACs. The ISO code of cutting tool
inserts and tool holder are shown in Table 2. The level
of variables used in the experiment is given in Table 3.
The schematic representation of cutting force
measurement is shown in Figure 2 and was measured
by using IEICOS Digital tool dynamometer
respectively. The measurement of cutting temperature
was carried out by thermocouple embedded in tool as
shown in Figure 3. For the thermocouple, a groove was
cut in the tool by using electrical discharge machining
(EDM). The groove was made in the rake face 1.70 mm
3. G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao 23
from the cutting edge and the thermocouple wire was
placed in the groove near the cutting edge Figure 4
shows the photograph of tool embedded with
thermocouple. This was chosen due to the combination
of getting good results in a shorter interval than other
method, and because of its ease in implementation after
it has been calibrated, and also due to its low cost [34,
35].
Table 1. Nominal chemical composition of base metal (6061 Al alloy).
Figure 2. The schematic representation of cutting force (Fz) measurement.
Table 2. Details of cutting tool and tooling system used for experimentation.
Tool holder Specification STGCR 2020 K-16
CTGPR 1212 F 11
Tool geometry Specification Approach angle:910
Tool nose radius:0.4 mm
Rake angle: 00
Clearance angle: 70
Tool insert CBN (KB-90)
Specification
TPGN160304-LS
TPGN 110304-LS
Element Cu Mg Si Cr Al
Weight. percentage 0.25 1.0 0.6 0.25 Balance
4. 24 G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao
Figure 3. Thermocouple embedded in the tool.
Figure 4. Thermocouple position in the tool.
Table 3.Levels and factors.
Levels
(A)
Lubricated condition
(B)
Cutting speed (m/min)
(C)
Feed (mm/rev)
1 Dry 45 0.11
2 Oil water emulsions 73 0.18
3 Steam 101 0.25
2.3. Steam Generator and Steam Feeding System
The steam generator and steam feeding system are
developed in which jet flow parameters (pressure, flow
rate) and cooling distance (the distance between nozzle
and cutting zone) are controllable. Figure 5 shows the
steam generator and steam feeding system.
Figure 5. Steam generator and steam feeding system.
5. G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao 25
3. TAGUCHI’S METHOD
Taguchi techniques have been used widely in
engineering design [36, 37]. The main trust of the
Taguchi techniques is the use of parameter design,
which is an engineering method for product or process
design that focuses on determining the parameter
(factor) settings producing the best levels of a quality
characteristic (performance measure) with minimum
variation. Taguchi designs provide a powerful and
efficient method for designing processes that operate
consistently and optimally over a variety of conditions.
To determine the best design requires the use of a
strategically designed experiment which exposes the
process to various levels of design parameters.
Experimental design methods were developed in the
early years of 20th century and have been extensively
studied by statisticians since then, but they were not
easy to use by practitioners [37]. Taguchi’s approach to
design of experiments is easy to adopt and apply for
users with limited knowledge of statistics, hence it has
gained a wide popularity in the engineering and
scientific community. There have been plenty of recent
applications of Taguchi techniques to materials
processing for process optimization. Some of the
previous works are listed in [38–43]. In particular, it is
recommended for analyzing metal cutting problems for
finding the optimal combination of parameters [43].
3.1. Design of Experiments
The orthogonal array for two factors at three levels was
used for the elaboration of the plan of experiments the
array L27 was selected, which has 27 rows
corresponding to the number of tests (26 degrees of
freedom) with 13 columns at three levels. The factors
and the interactions are assigned to the columns.
The first column was assigned to the lubrication
condition (A), the second column to cutting speed (B),
the fifth column to the feed (C) and remaining were
assigned to interactions. The outputs to be studied were
the cutting temperature and the cutting force. Further,
an analysis of variance (ANOVA) was carried out
separately for each response.
4. RESULTS AND DISCUSSION
4.1. Cutting Force in Turning of DRACs
Figure 6 shows the comparison of cutting force (Fz) in
steam application with dry and oil water emulsion. It is
observed that the cutting force decreases with increase
in cutting speed [44] further cutting force was lower in
steam application, compared to dry and oil water
emulsion. In steam application, the cutting fluid is
supplied at high pressure and high velocity, which
penetrates in to the tool chip interface causing reduction
in frictional contribution to the cutting force, these
minute capillaries exist at the tool chip interface and as
the chip moves up it contacts mainly at the top of the
asperities, these points of contact zones creating
capillaries between the chip and the tool. These
capillaries draw in steam, which chemically react to
produce a thin solid film of low shear strength, which
keeps the chip and the tool apart, it causes reduction in
friction. During steam as cutting fluid, the cutting fluid
is fragmented into tiny globules and the size of which is
inversely proportional to the pressure of injection. The
velocity varies as a function of the square root of the
injection pressure. This high velocity facilitates better
penetration of the steam to the underside of the chip
facilitating its passage to the tool chip interface
resulting in the reduction of friction. Such a condition is
not possible in oil water emulsion, where no such
fragmentation is taking place and the kinetic energy of
the fluid jet is in no way comparable to that during
steam injection.
From the Figure 6 it can be observed that, cutting force
decreases with an increase in cutting speed. Under
smaller cutting speed, the tool cutting edge will impact
on the reinforcement particles, the impacted particles
will then either be dislodged from the matrix, without
harming the tool, or be embedded into the matrix,
ploughing on the tool flank, resulting in a higher order
cutting force. As the cutting speed increases, the tool
would cut better without ploughing, resulting in a drop
in cutting force.
6. 26 G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao
Figure 6. Variation of cutting force with cutting speed for different lubrication conditions (a) feed (0.11mm/rev) (b) feed
(0.18mm/rev) (c) feed (0.25 mm/rev).
4.2. Cutting Temperature in Turning of DRACs
The temperature cθ of machining DRACs is dependent
on the cutting speed V and the type of material pair
involved in machining and can be expressed as
b
c Vθ ∝ (1)
The comparison of cutting temperature in steam
lubrication with oil water emulsion and dry cutting with
varying speed and feed keeping depth of cut constant
are shown in Figure 7. The cutting temperature
observed in steam application is comparatively less to
that of oil water emulsion and dry cutting.
Cutting temperature plays a major role in deciding the
tool wear as well as wear mechanisms such as abrasion,
adhesion, diffusion, chemical action, etc. During the
application of oil water emulsion the heat is extracted
only by convective heat transfer, but during steam
lubrication, cooling occurs by convective as well as
evaporative heat transfer. During steam lubrication fluid
droplets due to their high velocity can puncture the
blanket of vapor formed and reach the hot tool
interfaces facilitating evaporative heat transfer, which is
more efficient than the convective heat transfer. Steam
application thus provides better lubrication and
effective heat transfer leading to low cutting
temperature than that is possible during oil water
emulsion and dry cutting. The influence on cutting
temperature in all three cases shows an increasing trend
Figure 7.
7. G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao 27
Figure 7. Variation of cutting temperature with cutting speed for different lubrication conditions (a) feed (0.11mm/rev) (b)
feed (0.18mm/rev) (c) feed (0.25 mm/rev).
4.3. Analysis of Variance (ANOVA) and Factor
Effects for Cutting Force and Cutting Temperature
In Taguchi’s DOE method, the term “signal” represents
the desirable value and "noise" represents the
undesirable value. The objective of using S/N ratio is to
obtain a measure of performance to develop products
and processes insensitive to noise factors. The S/N ratio
indicates the degree of the predictable performance of a
product or process in the presence of noise factors.
Process parameter settings with the highest S/N ratio
always yield the optimum quality with minimum
variance. The S/N ratio for each parameter level is
calculated by averaging the S/N ratios obtained when
the parameter is maintained at that level. Table 4 and
Table 5 shows the S/N ratios obtained for different
parameter levels.
Table 4. Response table for signal to noise ratios smaller is better cutting force (N).
Level Lubrication condition Cutting speed (m/min)
Feed(mm/rev)
1 -41.64 -41.84 -40.31
2 -41.18 -40.98 -40.99
3 -40.05 -40.05 -41.57
Delta 1.59 1.79 1.26
Rank 2 1 3
8. 28 G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao
Table 5. Response table for signal to noise ratios smaller is better (cutting temperature).
Level Lubrication condition Cutting speed (m/min)
Feed(mm/rev)
1 -53.09 -50.76 -50.82
2 -51.50 -51.23 -51.16
3 -48.92 -51.53 -51.53
Delta 4.17 0.77 0.71
Rank 1 2 3
The calculated S/N ratio for three factors on the cutting
force and cutting temperature during machining of
DRACs for each level is shown in Figures 8-9. As
shown in Table 4 and Figure 8 steam is a dominant
parameter on the cutting force followed by cutting
speed and feed. Hence from mean S/N graph for
Cutting force from quality characteristic considered in
the investigation “smaller the better” we can conclude
that selection of steam lubrication,101m/min cutting
speed and 0.11 depth of cut would be ideal for
machining of DRACs. Similarly for cutting
temperature, from mean S/N graph we can conclude
that selection of steam lubrication, 45m/min cutting
speed and 0.11mm/rev feed would be ideal for
machining of DRACs.
Figure 8. Mean S/N graph for cutting force (N).
9. G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao 29
Figure 9. Mean S/N graph for cutting temperature.
On the examination of the percentage of contribution
(P%) of the different factors Tables 6-7, for cutting
force and cutting temperature, it can be seen that
lubrication condition has the highest contribution of
about 35.11% for cutting force and 94% for cutting
temperature, Followed by cutting speed and feed.
Further Interactions (AxB),(AxC),(BXC) do not present
a statistical significance, nor a percentage of physical
significance of contribution to the cutting force. But
interactions (AxC), (BXC) present a statistical
significance, and a percentage of physical significance
of contribution to the cutting temperature.
Table 6. Analysis of variance for the cutting force (N).
Source DOF Seq SS Adj SS Adj MS F P
Percent
P (%)
(A)Lubrication condition 2 12.0988 12.0988 6.04938 55.85 0.000 35.11
(B)Cutting speed (m/min) 2 14.4414 14.4414 7.22071 66.66 0.000 41.91
(C)Feed (mm/rev) 2 7.1611 7.1611 3.58055 33.06 0.000 20.78
AXB 4 0.3877 0.3877 0.09694 0.89 0.510 0.56
AXC 4 0.9580 0.9580 0.23950 2.21 0.158 1.39
BXC 4 0.1650 0.1650 0.04126 0.38 0.817 0.24
Residual Error 8 0.8665 0.8665 0.10832
Total 26 36.0786 100
10. 30 G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao
Table 7.Analysis of variance for S/N ratios for cutting temperature.
Source DOF Seq SS Adj SS Adj MS F P
Percent
P (%)
(A)Lubrication condition 2 79.7457 79.7457 39.8729 10429.58 0.000 94
(B)Cutting speed (m/min) 2 2.6746 2.6746 1.3373 349.79 0.000 3.15
(C)Feed (mm/rev) 2 2.2479 2.2479 1.1240 293.99 0.000 2.65
AXB 4 0.0293 0.0293 0.0073 1.92 0.201 0.017
AXC 4 0.1547 0.1547 0.0387 10.11 0.003 0.091
BXC 4 0.1376 0.1376 0.0344 9.00 0.005 0.081
Residual Error 8 0.0306 0.0306 0.0038
Total 26 85.0204 100
4.4. Confirmatory Experiments
To predict and verify the improvement in the cutting
force and cutting temperature for machining of DRACs
by the turning process with respect to the chosen initial
parameter setting, verification tests are used. Figure 10
shows the comparison of cutting force and cutting
temperature values obtained by experiments with
Taguchi’s design of experiments for obtaining optimal
cutting condition for machining of DRACs using steam
lubrication. From the graphs shown below, it is clear
that the least value of cutting force 75.132 N is obtained
at a cutting speed of 101m/min and a feed of
0.11mm/rev under steam lubrication. Similarly, lowest
cutting temperature 250o
C was obtained for a cutting
speed of 45m/min and feed 0.11mm/rev under steam
lubrication. The minimum values of the cutting force
and cutting temperature matched with the values as
shown in the mean S/N graph Figures 8-9.
Figure 10. Shows the comparison of cutting force and cutting temperature values obtained by experiments.
5. CONCLUSIONS
The cutting force and cutting temperature were studied
in turning of DRACs with cubic boron nitride tool
under dry, oil water emulsion and steam lubricated
conditions using experimental and Taguchi’s orthogonal
array. From the study, it can be concluded that the
steam lubrication can replace the dry and oil water
emulsion if the parameters are chosen carefully.
However, the process is new and much further research
is needed. Based on the emperical study, the following
conclusions can be drawn:
1. The cutting force and cutting temperature were
found to be lower during steam cutting compared
to oil water emulsion and dry cutting.
2. The cutting force decreases with increase of
cutting speed and with increase in feed. The
cutting temperature increases with cutting speed
and feed.
3. The effect of lubrication condition is found to be
having highest physical as well as statistical
influence on the cutting force and cutting
temperature (94% and 35.11% respectively)
4. The cutting speed is found to be the influential
cutting parameter that affects cutting force and
cutting temperature of about 41.91% and 3.15%
respectively.
11. G.U. J. Sci., 22(1):21-32 (2009)/ Raviraj Shetty ♠
, R. Pai, S.S.Rao 31
5. Optimum machining condition from mean S/N
graph and from experimental results for cutting force is
selection of steam lubrication, 101m/min cutting speed
and 0.11mm/rev feed. Similarly for cutting temperature,
selection of steam lubrication, 45m/min cutting speed
and 0.11mm/rev feed would be ideal for machining of
DRACs.
6. The results of the study show that with a
proper selection of machining parameters, it is possible
to obtain a performance better in steam lubrication
condition in turning of DRACs.
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