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
Experimental investigation of tool wear in turning of inconel718 material rev...EditorIJAERD
This document summarizes an experimental investigation into tool wear during turning of Inconel718 material. It reviews the effects of various cutting conditions, tool geometries, and tool treatments on tool wear and other output parameters like cutting force, temperature, vibration, power consumption, surface roughness, and material removal rate. The goal is to analyze tool wear based on literature to optimize machining of Inconel718 using a CNC machine. Various studies investigating factors like cutting speed, feed rate, depth of cut, tool material, and cooling conditions are summarized to reduce tool wear during machining of this difficult-to-cut alloy.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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 ti n coated carbide insert for optimum surface roug...eSAT Journals
Abstract In manufacturing industry, beside the dimensional and geometric tolerance of a component, surface quality is most commonly specified requirements. Surface roughness plays an important role in the performance of the component. This paper presents a study of the influence of the cutting parameters on the surface roughness during the turning of AISI1045 steel with TiN coated carbide tool. The design of experiments based on the Taguchi technique. The objective was to optimization of the machining parameters as cutting speed, feed rate and depth of cut for surface roughness. Main effect plots are generated and analyzed to find out the relationship between them. Afterwords a confirmation test were performed to make a comparison between the predicted results and the theoretical results. Keywords: TiN carbide insert, AISI 1045 alloy steel, Taguchi method, Surface roughness, ANOVA
This document summarizes a seminar report on the effect of casting process parameters on the mechanical properties of aluminum alloys. It discusses how parameters like pouring temperature, cooling time, mold hardness, sand particle size, and pouring speed can influence properties such as tensile strength, hardness, and impact strength. The objectives are to study how these parameters affect mechanical properties and to minimize casting defects by optimizing parameter values. Several authors have used the Taguchi technique to optimize process parameters to improve mechanical properties of aluminum castings.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
2nd progress presentation on Minimum Quantity Lubrication(MQL) with vegitable...Nadaraja Sarmilan
This is a research based project of improving machining process as well as the environmental conditions using novel coconut oil based cutting fluid under Minimum Quantity Lubrication(MQL). In order to achieve the testing situations, the conceptual design of the experimental setup was finalized by following best solutions given through the morphological analysis of existing MQL systems. Solid models of nozzles, nozzle holding component, MWF tank, MWF tank support and finalized experimental setup were designed by solid modeling software. To corroboration the importance of novel vegetable oil based lubricant, the machining performances such as surface roughness and chip formation were evaluated.
A Literature Review on Optimization of Input Cutting Parameters for Improved ...IRJET Journal
This document reviews literature on optimizing input cutting parameters to improve surface finish in turning processes. It aims to present various methodologies for predicting surface roughness. The literature compiles works on optimizing process parameters like cutting speed, feed rate, depth of cut, insert radius, and cutting fluid. It is concluded that these parameters most significantly impact surface roughness. Optimization techniques commonly used include Taguchi methodology, response surface methodology, full factorial analysis, and neural networks. The document provides a table summarizing 18 research papers on this topic, including details on materials machined, cutting parameters analyzed, outputs measured, and optimization methods employed.
Experimental investigation of tool wear in turning of inconel718 material rev...EditorIJAERD
This document summarizes an experimental investigation into tool wear during turning of Inconel718 material. It reviews the effects of various cutting conditions, tool geometries, and tool treatments on tool wear and other output parameters like cutting force, temperature, vibration, power consumption, surface roughness, and material removal rate. The goal is to analyze tool wear based on literature to optimize machining of Inconel718 using a CNC machine. Various studies investigating factors like cutting speed, feed rate, depth of cut, tool material, and cooling conditions are summarized to reduce tool wear during machining of this difficult-to-cut alloy.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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 ti n coated carbide insert for optimum surface roug...eSAT Journals
Abstract In manufacturing industry, beside the dimensional and geometric tolerance of a component, surface quality is most commonly specified requirements. Surface roughness plays an important role in the performance of the component. This paper presents a study of the influence of the cutting parameters on the surface roughness during the turning of AISI1045 steel with TiN coated carbide tool. The design of experiments based on the Taguchi technique. The objective was to optimization of the machining parameters as cutting speed, feed rate and depth of cut for surface roughness. Main effect plots are generated and analyzed to find out the relationship between them. Afterwords a confirmation test were performed to make a comparison between the predicted results and the theoretical results. Keywords: TiN carbide insert, AISI 1045 alloy steel, Taguchi method, Surface roughness, ANOVA
This document summarizes a seminar report on the effect of casting process parameters on the mechanical properties of aluminum alloys. It discusses how parameters like pouring temperature, cooling time, mold hardness, sand particle size, and pouring speed can influence properties such as tensile strength, hardness, and impact strength. The objectives are to study how these parameters affect mechanical properties and to minimize casting defects by optimizing parameter values. Several authors have used the Taguchi technique to optimize process parameters to improve mechanical properties of aluminum castings.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
2nd progress presentation on Minimum Quantity Lubrication(MQL) with vegitable...Nadaraja Sarmilan
This is a research based project of improving machining process as well as the environmental conditions using novel coconut oil based cutting fluid under Minimum Quantity Lubrication(MQL). In order to achieve the testing situations, the conceptual design of the experimental setup was finalized by following best solutions given through the morphological analysis of existing MQL systems. Solid models of nozzles, nozzle holding component, MWF tank, MWF tank support and finalized experimental setup were designed by solid modeling software. To corroboration the importance of novel vegetable oil based lubricant, the machining performances such as surface roughness and chip formation were evaluated.
A Literature Review on Optimization of Input Cutting Parameters for Improved ...IRJET Journal
This document reviews literature on optimizing input cutting parameters to improve surface finish in turning processes. It aims to present various methodologies for predicting surface roughness. The literature compiles works on optimizing process parameters like cutting speed, feed rate, depth of cut, insert radius, and cutting fluid. It is concluded that these parameters most significantly impact surface roughness. Optimization techniques commonly used include Taguchi methodology, response surface methodology, full factorial analysis, and neural networks. The document provides a table summarizing 18 research papers on this topic, including details on materials machined, cutting parameters analyzed, outputs measured, and optimization methods employed.
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.
Prediction of Tool Life of Different Coated Cutting Tools During Machining of...IRJET Journal
This document summarizes research on predicting the tool life of different coated cutting tools during machining of Inconel 718. Two coatings, TiAlSiN and TiAlN, were deposited on tungsten carbide end mills. Experiments were conducted to analyze tool wear and surface roughness at various cutting speeds, feeds, and depths of cut. The results showed that coated tools performed better than uncoated tools with longer tool life. TiAlSiN coated tools performed the best with the longest tool life. As flank wear increased with cutting time, the surface roughness of the machined parts also increased. Cutting forces generally increased with progression of tool wear and other factors like work hardening. Higher cutting speeds and feeds led
Experimental Analysis of Machining Parameters on Turning with Single Point Cu...ijtsrd
This document summarizes an experimental analysis of machining parameters when using a single point cutting tool in turning operations. The experiment tested various spindle speeds, feed rates, and depths of cut to determine their effects on surface roughness, tool life, and material removal rate (MRR). Tests were conducted on a lathe using a high-speed steel single point tool to machine S50C medium carbon steel. Results showed that higher speeds, feeds, and depths increased MRR but decreased tool life. Surface roughness also increased at higher speeds. The analysis provides equations to calculate cutting forces, tool life, surface roughness, and MRR based on the machining parameters. Graphs of the results are also presented. In conclusion, the optimal mach
COMPARISON OF MAIN EFFECT OF VEGETABLE OIL AND AL2O3 NANOFLUIDS USED WITH MQL...IAEME Publication
The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Application of cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. But the conventional cutting fluids are not that effective in such high production machining, particularly in continuous cutting of materials likes steels. So Nanofluids have novel properties that make them potentially useful in heat transfer medium in cutting zone and Minimum quantity lubrication (MQL) presents itself as a viable alternative for turning with respect to tool wear, heat dissipation, and machined surface quality.
Vegetable Oil Based Minimum Quantity Lubrication (MQL) During MachiningNadaraja Sarmilan
This document summarizes an experimental study that compared vegetable oil-based and mineral oil-based minimum quantity lubrication (MQL) during machining. Mild steel and stainless steel were machined under different conditions and their surface roughness, chip formation, tool wear, and chip-tool interface temperature were evaluated. Key results included the vegetable oil MQL providing better surface finish for mild steel, better chip formation for both materials, and lower tool wear and interface temperatures for stainless steel, compared to the mineral oil MQL. The study determined optimal cutting parameters for stainless steel of 45 rpm spindle speed, 5.231 m/min cutting speed, and 0.186 ml/s vegetable oil flow rate, which produced the lowest interface temperature
Review on investigation and optimization of turning process parameter in wet ...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
The document discusses the use of metal working fluids in manufacturing processes and the issues with traditional wet machining techniques. It proposes that minimum quantity lubrication (MQL) is a more sustainable alternative that uses much smaller amounts of cutting fluid compared to flood cooling. MQL has benefits such as lower costs, reduced tool wear, better surface finish, and fewer environmental and health impacts compared to wet machining.
The document experimentally investigates the material removal rate (MRR) and tool wear in turning hardened AISI 52100 steel using the Taguchi technique. Experiments were conducted using different cutting speeds, feed rates, and depths of cut based on an L9 orthogonal array. The results were analyzed using signal-to-noise ratios and ANOVA to determine the optimal process parameters for maximizing MRR and minimizing tool wear. The analysis found that cutting speed had the greatest influence on MRR, followed by depth of cut and feed rate. The optimal parameters for MRR were a cutting speed of 1120 rpm, feed rate of 0.12 mm/rev, and depth of cut of 0.4 mm.
IRJET- Experimental Investigation of Aluminum 7075 using Dry, Wet and MQL...IRJET Journal
The document experimentally investigates the effect of dry, wet, and minimum quantity lubrication (MQL) conditions on machining aluminum 7075 alloy. Surface roughness and temperature near the cutting zone were analyzed for each condition. MQL machining resulted in lower surface roughness and temperature compared to dry and wet machining. Gray relational analysis determined that for dry machining, a cutting speed of 10000 rpm, feed rate of 600 mm/min, and depth of cut of 0.25 mm provided the best performance across surface roughness and temperature.
Study of Manufacturing of Multi-Saddle ClampIRJET Journal
The document discusses the design and manufacturing of a multi-saddle clamp die. Previously, single cavity dies were used to manufacture individual saddle clamps through bending or blanking operations. However, this was an inefficient process. The proposed multi-saddle clamp die allows for multiple clamps to be manufactured simultaneously through bending and blanking operations in the same die, improving productivity. Key requirements for the die design include producing quality products efficiently while minimizing manufacturing costs and scrap material. The methodology involves identifying the problem, collecting information, and developing a solution to design a die that can manufacture multiple saddle clamps in a single cycle through different operations like surface grinding, drilling, tapping, and wire drawing.
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
This document presents a comparative analysis of surface roughness and material removal rate during milling of AISI 410 steel and aluminum 6061. Experiments were conducted using a CNC milling machine varying spindle speed, feed rate, and depth of cut. Response surface methodology was used to optimize surface roughness. The results showed that for AISI 410 steel, spindle speed had the greatest effect on material removal rate and surface roughness, while for aluminum 6061, no parameters significantly affected the responses. Overall, different milling parameters impacted the materials differently in terms of surface finish and productivity.
Review of Effect of Tool Nose Radius on Cutting Force and Surface RoughnessIRJET Journal
This document reviews the effect of tool nose radius on cutting force and surface roughness in machining processes. It summarizes several previous studies that have examined how tool nose radius influences factors like surface finish, tool wear, cutting forces, heat generation, and residual stresses. The studies found that larger tool nose radii generally produce finer surface finishes but greater tool wear. Increasing nose radius also tends to increase cutting forces but decrease surface roughness. The document aims to further evaluate how nose radius affects cutting force, tool wear, and residual stresses in metal turning.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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.
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.
Optimizing of High Speed Turning Parameters of Inconel 625 (Super Alloy) by u...IRJET Journal
This document discusses optimizing cutting parameters for high speed turning of Inconel 625 super alloy using the Taguchi technique. Inconel 625 is difficult to machine due to its properties. The study aims to determine optimal cutting speed, feed rate, and depth of cut to minimize surface roughness and maximize material removal rate. Experiments are conducted on a CNC turning machine using tungsten carbide tools and Taguchi's L9 orthogonal array. The cutting forces and responses of surface roughness and material removal rate are measured. Regression and Taguchi design of experiments methods are used for analysis to determine the optimal cutting parameters for high speed machining of Inconel 625 super alloy.
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
This study evaluated the influence of tellurium content and minimum quantity lubrication (MQL) flow rate on drilling performance when drilling microalloyed steel. Two grades of steel were tested, one with high tellurium content and one with low tellurium content. Drilling tests were conducted using two cutting speeds, two feed rates, two drill geometries, and two MQL flow rates. Statistical analysis showed that tellurium content most significantly impacted performance, doubling drill life for the high tellurium steel. MQL flow rate had the lowest influence, with a higher flow only reducing life 9%. Addition of tellurium improved machinability by reducing forces during chip formation.
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.
Sentence level sentiment polarity calculation for customer reviews by conside...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
This document summarizes a study on evaluating the performance of intake tower dams in India during recent earthquakes. Intake towers are tall, hollow reinforced concrete structures that form the entrance to reservoir outlet works. The study aims to understand how parameters like depth of submergence, wall thickness, and slenderness ratio affect the dynamic behavior of intake towers during earthquakes. A simplified circular cylindrical tower model was analyzed in SAP2000 considering hydrodynamic added mass from surrounding and inside water. Dynamic analyses including modal and time history analyses were performed for different soil conditions and earthquakes in India from 2005-2013. The results show the effect of these parameters and soil conditions on the displacement and acceleration response of the intake towers.
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.
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.
Prediction of Tool Life of Different Coated Cutting Tools During Machining of...IRJET Journal
This document summarizes research on predicting the tool life of different coated cutting tools during machining of Inconel 718. Two coatings, TiAlSiN and TiAlN, were deposited on tungsten carbide end mills. Experiments were conducted to analyze tool wear and surface roughness at various cutting speeds, feeds, and depths of cut. The results showed that coated tools performed better than uncoated tools with longer tool life. TiAlSiN coated tools performed the best with the longest tool life. As flank wear increased with cutting time, the surface roughness of the machined parts also increased. Cutting forces generally increased with progression of tool wear and other factors like work hardening. Higher cutting speeds and feeds led
Experimental Analysis of Machining Parameters on Turning with Single Point Cu...ijtsrd
This document summarizes an experimental analysis of machining parameters when using a single point cutting tool in turning operations. The experiment tested various spindle speeds, feed rates, and depths of cut to determine their effects on surface roughness, tool life, and material removal rate (MRR). Tests were conducted on a lathe using a high-speed steel single point tool to machine S50C medium carbon steel. Results showed that higher speeds, feeds, and depths increased MRR but decreased tool life. Surface roughness also increased at higher speeds. The analysis provides equations to calculate cutting forces, tool life, surface roughness, and MRR based on the machining parameters. Graphs of the results are also presented. In conclusion, the optimal mach
COMPARISON OF MAIN EFFECT OF VEGETABLE OIL AND AL2O3 NANOFLUIDS USED WITH MQL...IAEME Publication
The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Application of cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. But the conventional cutting fluids are not that effective in such high production machining, particularly in continuous cutting of materials likes steels. So Nanofluids have novel properties that make them potentially useful in heat transfer medium in cutting zone and Minimum quantity lubrication (MQL) presents itself as a viable alternative for turning with respect to tool wear, heat dissipation, and machined surface quality.
Vegetable Oil Based Minimum Quantity Lubrication (MQL) During MachiningNadaraja Sarmilan
This document summarizes an experimental study that compared vegetable oil-based and mineral oil-based minimum quantity lubrication (MQL) during machining. Mild steel and stainless steel were machined under different conditions and their surface roughness, chip formation, tool wear, and chip-tool interface temperature were evaluated. Key results included the vegetable oil MQL providing better surface finish for mild steel, better chip formation for both materials, and lower tool wear and interface temperatures for stainless steel, compared to the mineral oil MQL. The study determined optimal cutting parameters for stainless steel of 45 rpm spindle speed, 5.231 m/min cutting speed, and 0.186 ml/s vegetable oil flow rate, which produced the lowest interface temperature
Review on investigation and optimization of turning process parameter in wet ...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
The document discusses the use of metal working fluids in manufacturing processes and the issues with traditional wet machining techniques. It proposes that minimum quantity lubrication (MQL) is a more sustainable alternative that uses much smaller amounts of cutting fluid compared to flood cooling. MQL has benefits such as lower costs, reduced tool wear, better surface finish, and fewer environmental and health impacts compared to wet machining.
The document experimentally investigates the material removal rate (MRR) and tool wear in turning hardened AISI 52100 steel using the Taguchi technique. Experiments were conducted using different cutting speeds, feed rates, and depths of cut based on an L9 orthogonal array. The results were analyzed using signal-to-noise ratios and ANOVA to determine the optimal process parameters for maximizing MRR and minimizing tool wear. The analysis found that cutting speed had the greatest influence on MRR, followed by depth of cut and feed rate. The optimal parameters for MRR were a cutting speed of 1120 rpm, feed rate of 0.12 mm/rev, and depth of cut of 0.4 mm.
IRJET- Experimental Investigation of Aluminum 7075 using Dry, Wet and MQL...IRJET Journal
The document experimentally investigates the effect of dry, wet, and minimum quantity lubrication (MQL) conditions on machining aluminum 7075 alloy. Surface roughness and temperature near the cutting zone were analyzed for each condition. MQL machining resulted in lower surface roughness and temperature compared to dry and wet machining. Gray relational analysis determined that for dry machining, a cutting speed of 10000 rpm, feed rate of 600 mm/min, and depth of cut of 0.25 mm provided the best performance across surface roughness and temperature.
Study of Manufacturing of Multi-Saddle ClampIRJET Journal
The document discusses the design and manufacturing of a multi-saddle clamp die. Previously, single cavity dies were used to manufacture individual saddle clamps through bending or blanking operations. However, this was an inefficient process. The proposed multi-saddle clamp die allows for multiple clamps to be manufactured simultaneously through bending and blanking operations in the same die, improving productivity. Key requirements for the die design include producing quality products efficiently while minimizing manufacturing costs and scrap material. The methodology involves identifying the problem, collecting information, and developing a solution to design a die that can manufacture multiple saddle clamps in a single cycle through different operations like surface grinding, drilling, tapping, and wire drawing.
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
This document presents a comparative analysis of surface roughness and material removal rate during milling of AISI 410 steel and aluminum 6061. Experiments were conducted using a CNC milling machine varying spindle speed, feed rate, and depth of cut. Response surface methodology was used to optimize surface roughness. The results showed that for AISI 410 steel, spindle speed had the greatest effect on material removal rate and surface roughness, while for aluminum 6061, no parameters significantly affected the responses. Overall, different milling parameters impacted the materials differently in terms of surface finish and productivity.
Review of Effect of Tool Nose Radius on Cutting Force and Surface RoughnessIRJET Journal
This document reviews the effect of tool nose radius on cutting force and surface roughness in machining processes. It summarizes several previous studies that have examined how tool nose radius influences factors like surface finish, tool wear, cutting forces, heat generation, and residual stresses. The studies found that larger tool nose radii generally produce finer surface finishes but greater tool wear. Increasing nose radius also tends to increase cutting forces but decrease surface roughness. The document aims to further evaluate how nose radius affects cutting force, tool wear, and residual stresses in metal turning.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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.
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.
Optimizing of High Speed Turning Parameters of Inconel 625 (Super Alloy) by u...IRJET Journal
This document discusses optimizing cutting parameters for high speed turning of Inconel 625 super alloy using the Taguchi technique. Inconel 625 is difficult to machine due to its properties. The study aims to determine optimal cutting speed, feed rate, and depth of cut to minimize surface roughness and maximize material removal rate. Experiments are conducted on a CNC turning machine using tungsten carbide tools and Taguchi's L9 orthogonal array. The cutting forces and responses of surface roughness and material removal rate are measured. Regression and Taguchi design of experiments methods are used for analysis to determine the optimal cutting parameters for high speed machining of Inconel 625 super alloy.
Influence of tellurium addition on drilling of microalloyed steel (din 38mns6)Lepuufu
This study evaluated the influence of tellurium content and minimum quantity lubrication (MQL) flow rate on drilling performance when drilling microalloyed steel. Two grades of steel were tested, one with high tellurium content and one with low tellurium content. Drilling tests were conducted using two cutting speeds, two feed rates, two drill geometries, and two MQL flow rates. Statistical analysis showed that tellurium content most significantly impacted performance, doubling drill life for the high tellurium steel. MQL flow rate had the lowest influence, with a higher flow only reducing life 9%. Addition of tellurium improved machinability by reducing forces during chip formation.
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.
Sentence level sentiment polarity calculation for customer reviews by conside...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
This document summarizes a study on evaluating the performance of intake tower dams in India during recent earthquakes. Intake towers are tall, hollow reinforced concrete structures that form the entrance to reservoir outlet works. The study aims to understand how parameters like depth of submergence, wall thickness, and slenderness ratio affect the dynamic behavior of intake towers during earthquakes. A simplified circular cylindrical tower model was analyzed in SAP2000 considering hydrodynamic added mass from surrounding and inside water. Dynamic analyses including modal and time history analyses were performed for different soil conditions and earthquakes in India from 2005-2013. The results show the effect of these parameters and soil conditions on the displacement and acceleration response of the intake towers.
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.
The document describes a system to monitor and control liquid flow in pipelines using a Raspberry Pi, Arduino, and other hardware components. A Hall effect sensor measures the liquid flow rate, which is read by an Arduino and sent to a Raspberry Pi. The Raspberry Pi controls an electro-valve connected to the pipeline and hosts a web server to monitor and control the flow remotely over the Internet. The system was tested successfully with a water pipeline setup and allows remote monitoring and control of liquid flows in industrial processes.
Detect and overcome the selfish problem in wifi network using energy sharingeSAT 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
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.
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
Key frame extraction for video summarization using motion activity descriptorseSAT 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
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.
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
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.
An experimental study of square footing resting on geo grid reinforced sandeSAT 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
This document discusses partial encryption of compressed video. It proposes a method where only crucial parts of compressed video are encrypted, rather than encrypting the entire video stream. This results in significant reductions in processing time, computational requirements, bit rate, and bandwidth needed for encryption and transmission. The document provides background on video compression standards like MPEG-4 and encryption techniques. It then describes testing of the partial encryption method on images and outlines the problems with fully encrypting video streams that partial encryption aims to address.
Influence of alkaline substances (carbonates and bicarbonates of sodium) in w...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.
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
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.
This study examined the effect of two bacteria - Bacillus sphaericus and Sporosarcina pasteurii - on cement composites. The bacteria were added to cement paste, mortar, and concrete at a concentration of 106 cells/ml. Compressive strength was found to increase by 39.8% and 33.07% for paste, 50% and 28.2% for mortar, and 18.3% and 12.2% for concrete when using the two bacterial strains respectively. SEM and XRD analysis revealed the presence of calcium carbonate precipitated by the bacterial activity, which improved the strength and durability of the cement composites.
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
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.
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
SolidCAM iMachining technology positive effects on cutting tool life during m...IRJET Journal
The document analyzes the effects of using SolidCAM iMachining technology on tool wear during machining of stainless steel AISI 304. Key findings include:
1) Tool life was increased significantly, with a tool expected to last 200-300 minutes instead lasting around 1000 minutes with minimal dimensional changes in the workpiece.
2) Dimensions of machined parts were measured after machining sets of 20 pieces and found to remain within tolerance limits.
3) Tool wear analysis found some initial chipping but the engaged cutting edge showed no significant wear features, attributed to use of an appropriate AlTiN+ coating.
IRJET- Selection for Better and Increased Tool Life by the Use of HSS Cutting...IRJET Journal
This document summarizes a research study that evaluated the optimal cutting parameters for maximum tool life when machining mild steel and aluminum with HSS cutting tools under dry conditions. Experiments were conducted using different spindle speeds, cutting speeds, and feed rates to determine their effects on depth of cut and tool life. Results showed that higher spindle speeds and feeds decreased tool life for both materials. Mild steel provided longer tool life than aluminum. The study aimed to identify cutting conditions for improved tool life by selecting appropriate workpiece and cutting tool materials along with suitable feed rates and lower cutting speeds.
IRJET- Improving the Performance of M42 Twist Drill ToolIRJET Journal
This document summarizes an experiment to optimize the heat treatment process and improve the performance of M42 twist drill tools. The experiment tested different materials, heat treatment cycles, spindle speeds, and point angles. Testing found that M42 material exhibited the lowest wear and temperature, making it the best material. Further testing determined that a point angle of 118 degrees and spindle speed of 750 RPM provided the best performance. In total, the experiment aimed to optimize the drill tool design and heat treatment process to improve tool life, hardness, and reduce costs.
IRJET- Review Paper Optimizationof MachiningParametersbyusing of Taguchi'...IRJET Journal
This document summarizes an experimental study that used the Taguchi method to optimize machining parameters for turning AA6063 alloy steel. The study aimed to maximize the material removal rate (MRR) by investigating the effects of cutting speed, depth of cut, and feed rate. A number of turning experiments were conducted using an L9 orthogonal array with different combinations of the machining parameters. Analysis of the experimental results found that feed rate had the greatest influence on MRR, followed by depth of cut. The Taguchi method was effective for determining the optimal machining parameters for maximizing the material removal rate during turning of AA6063 alloy steel.
Performance of machining parameters on powder metals by using PCBN tool and c...IRJET Journal
This document summarizes a study on the effects of machining parameters on the surface roughness of powder metals machined using PCBN and carbide tools. The study involved conducting milling experiments on powder metal steel, varying spindle speed, feed rate, and depth of cut. Analysis of variance was used to determine the significance of each parameter on surface roughness. The experiments found that increased feed rate improved tool life for PCBN tools, while lower feed rate improved tool life for carbide tools. Cutting speed also significantly impacted tool life, with lower speeds leading to longer tool life. The study provided insight into optimizing cutting conditions to increase tool life when machining powder metals.
IRJET- Design and Fabrication of Skiving and Burnishing ToolIRJET Journal
This document describes the design and fabrication of a skiving and burnishing tool. It discusses how skiving is used to cut thin slices of material and burnishing is used to improve surface finish without removing material. The authors designed tools for skiving and burnishing on a lathe using high speed steel materials. They fabricated prototypes of the tools and tested them on a mild steel workpiece. The design and fabrication process achieved the goal of efficiently performing skiving and burnishing operations on a lathe.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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IRJET- Optimization Machining Parameters in a Turning Operation of Steels to ...IRJET Journal
The document presents an experimental study to optimize machining parameters during turning operations of different steel grades to minimize surface roughness and temperature. The study uses Taguchi methodology to determine the effects of cutting speed, feed rate, and depth of cut on temperature, hardness, and surface roughness. Experiments were conducted turning EN8 steel, mild steel, and OHNS steel using tungsten and cemented carbide inserts. Results from Taguchi analysis and ANOVA showed that cutting speed has the most significant impact on surface roughness and hardness, while depth of cut alone significantly impacts temperature. The optimum parameters were identified to minimize surface roughness and temperature for the different materials.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IRJET-Optimization of Machining Parameters Affecting Metal Removal Rate of Al...IRJET Journal
The document discusses optimizing machining parameters to increase the metal removal rate in dry end milling of aluminum alloy 6082. The machining parameters investigated are spindle speed, feed rate, and depth of cut. Experiments were performed using a Taguchi design of experiments with the parameters tested at three levels. The experimental data was analyzed using Minitab software to identify the most significant factor affecting metal removal rate. The goal is to determine the optimal settings of the machining parameters to maximize productivity during end milling of aluminum alloy 6082.
IRJET- Review Paper Optimization of Machining Parameters by using of Taguchi'...IRJET Journal
This document summarizes a research paper that used the Taguchi method to optimize machining parameters for turning operations on EN-31 alloy steel. The paper conducted experiments using various cutting speeds, feed rates, and depths of cut. The Taguchi design of experiments approach was used to determine the optimal machining parameters that maximize material removal rate. Analysis with MINITAB statistical software found that feed rate had the greatest influence on surface roughness, while cutting speed most significantly impacted cutting forces. The optimized parameters can improve the efficiency and cost-effectiveness of turning EN-31 alloy steel.
Cutting Parameters Optimization in Milling Of P – 20 Tool Steel And EN31B IOSR Journals
The objective of the paper is to obtain an optimal setting of CNC machining process parameters,
cutting speed, feed rate resulting in optimal values of the feed and radial forces while machining P – 20 tool
steel and EN31B with TiN coated tungsten carbide inserts. The effects of the selected process parameters on the
chosen characteristics and the subsequent optimal settings of the parameters have been accomplished using
Taguchi’s parameter design approach.The process parameters considered are – Cutting speed 3000rpm,
2500rpm and 2000rpm. Feed rate 200mm/min, 300mm/min and 400mm/min and depth of cut is 0.2mm.The
effect of these parameters on the feed force, radial force are considered for analysis.The analysis of the results
shows that the optimal settings for low values of feed and radial forces are high cutting speed, low feed rate and
depth of cut.The thrust force and feed force are also taken experimentally using dynamometer for above Cutting
speeds, feed rate and depth of cut. The optimal values for speed, feed rate and depth of cut are taken using
Taguchi technique.Taguchi methods are statistical methods developed by Genichi Taguchi to improve the
quality of manufactured goods, and more recently also applied to, engineering, biotechnology, marketing and
advertising.Process used in this project is milling process. Machine selected is Vertical milling center. Machine
model selected is BFW Agni 45. Modeling is done in Pro/Engineer and analysis is done in ANSYS.
IRJET- Optimization of Control Factors for Machining Time in CNC Milling ...IRJET Journal
This document discusses using the Taguchi method to optimize machining parameters for CNC milling of Al-7075 based metal matrix composites (MMCs). The goal is to minimize machining time. Spindle speed, feed rate, and depth of cut were selected as control factors, each with three levels. Nine experiments were conducted using an L9 orthogonal array. The machining time was measured as the response. Signal-to-noise ratios were calculated to determine the optimal levels for minimizing machining time. The results will help identify process parameters that maximize efficiency during CNC milling of MMCs.
IRJET- Experimental Analysis and Geometrical Effect on Mild Steel with Un...IRJET Journal
This document describes an experimental analysis of drilling mild steel with both uncoated and tungsten carbide coated high-speed steel drill bits using the Taguchi technique. The experiment analyzed the impact of drilling speed, feed rate, and depth of cut on surface roughness, hole diameter, and material removal rate. Experiments were conducted on a CNC milling machine without cutting fluid. Results for the uncoated and coated drilling were collected and analyzed using Minitab software to determine the optimal drilling parameters.
IRJET- Performance Enhancement of Cutting Tools by using Cryogenic TreatmentsIRJET Journal
This document summarizes a study on improving the performance of micro cutting tools through cryogenic treatment. Cryogenic treatment involves submerging tools in liquid nitrogen or carbon dioxide to enhance hardness. The study examines how cryogenic treatment of tungsten carbide tools at different temperatures and soaking periods affects cutting forces and surface roughness when grinding titanium alloy at the micro-scale. Results show that deeper cryogenic treatment (-196°C) for longer durations (24 hours) leads to lower cutting forces, better surface finish, and increased tool life compared to untreated tools due to improved hardness from precipitation of eta carbide in the tool material. Therefore, cryogenic treatment is concluded to enhance the mechanical properties and performance of micro cutting tools.
Optimization of Surface Roughness Parameters in Turning EN1A Steel on a CNC L...IRJET Journal
This document summarizes an experiment to optimize surface roughness parameters when turning EN1A steel on a CNC lathe with coolant. The experiment uses Taguchi methods to design the experiment with three factors (cutting speed, feed rate, and depth of cut) at three levels each, for a total of nine experiments. Analysis of variance is used to analyze the results and determine that feed rate has the highest contribution to surface roughness at 68.56%, followed by cutting speed at 18.98% and depth of cut at 12.46%. Regression and general linear models are developed to model the relationship between the input and output parameters. The results provide optimal cutting conditions and are useful for manufacturing industries to improve surface finish.
Impact of Mechanical System in Machining Of AISI 1018 Using Taguchi Design o...IJMER
The imperative objective of the science of metal cutting is the solution of practical problems
associated with the efficient and precise removal of metal from work piece. Optimization of process
parameters is done to have great control over quality, productivity and cost aspects of the process.
Taguchi method stresses the importance of studying the response variation using the signal–to–noise
(S/N) ratio, resulting in minimization of quality characteristic variation due to uncontrollable
parameter. Orthogonal array was adopted in order to planning the (L9) experimental runs in turning of
AISI 1018 by taking the help of software Minitab 16. The MRR and time
Optimization of Tool Path and Process Parameters in Slot Milling using Grey R...IRJET Journal
This document summarizes a research study that aimed to optimize the tool path and process parameters for slot milling of AISI D3 steel. The study investigated different tool paths (raster, trochoidal, hybrid) at various cutting speeds and feed rates using a Taguchi experimental design. Surface roughness and cutting forces were measured for each experimental run. Grey relational analysis was used to analyze the results and identify the optimal tool path and cutting conditions that minimized surface roughness and cutting forces. The results of the study will help manufacturers select machining parameters that improve part quality while reducing production costs.
This document summarizes research measuring tool flank wear when machining Inconel 825. The research was conducted in two stages:
1. Dry turning of Inconel 825 was performed on a CNC machine using uncoated carbide tools. Tool flank wear was measured under varying spindle speeds from 300-900 RPM and feeds of 0.06, 0.08, and 0.1 mm/rev.
2. Dry turning of Inconel 825 was also performed on a conventional lathe under varying cutting conditions. Tool flank wear was again measured.
The goal of the research was to compare tool flank wear when machining Inconel 825 on a CNC machine versus a conventional
Similar to An experiental investigation of effect of cutting parameters and tool materials on tool life and productivity in turning of cylinder liners (20)
Hudhud cyclone caused extensive damage in Visakhapatnam, India in October 2014, especially to tree cover. This will likely impact the local environment in several ways: increased air pollution as trees absorb less; higher temperatures without tree canopy; increased erosion and landslides. It also created large amounts of waste from destroyed trees. Proper management of solid waste is needed to prevent disease spread. Suggested measures include restoring damaged plants, building fountains to reduce heat, mandating light-colored buildings, improving waste management, and educating public on health risks. Overall, changes are needed to water, land, and waste practices to rebuild the environment after the cyclone removed green cover.
Impact of flood disaster in a drought prone area – case study of alampur vill...eSAT Publishing House
1) In September-October 2009, unprecedented heavy rainfall and dam releases caused widespread flooding in Alampur village in Mahabub Nagar district, a historically drought-prone area.
2) The flood damaged or destroyed homes, buildings, infrastructure, crops, and documents. It displaced many residents and cut off the village.
3) The socioeconomic conditions and mud-based construction of homes in the village exacerbated the flood's impacts, making damage more severe and recovery more difficult.
The document summarizes the Hudhud cyclone that struck Visakhapatnam, India in October 2014. It describes the cyclone's formation, rapid intensification to winds of 175 km/h, and landfall near Visakhapatnam. The cyclone caused extensive damage estimated at over $1 billion and at least 109 deaths in India and Nepal. Infrastructure like buildings, bridges, and power lines were destroyed. Crops and fishing boats were also damaged. The document then discusses coping strategies and improvements needed to disaster management plans to better prepare for future cyclones.
Groundwater investigation using geophysical methods a case study of pydibhim...eSAT Publishing House
This document summarizes the results of a geophysical investigation using vertical electrical sounding (VES) methods at 13 locations around an industrial area in India. The VES data was interpreted to generate geo-electric sections and pseudo-sections showing subsurface resistivity variations. Three main layers were typically identified - a high resistivity topsoil, a weathered middle layer, and a basement rock. Pseudo-sections revealed relatively more weathered areas in the northwest and southwest. Resistivity sections helped identify zones of possible high groundwater potential based on low resistivity anomalies sandwiched between more resistive layers. The study concluded the electrical resistivity method was useful for understanding subsurface geology and identifying areas prospective for groundwater exploration.
Flood related disasters concerned to urban flooding in bangalore, indiaeSAT Publishing House
1. The document discusses urban flooding in Bangalore, India. It describes how factors like heavy rainfall, population growth, and improper land use have contributed to increased flooding in the city.
2. Flooding events in 2013 are analyzed in detail. A November rainfall caused runoff six times higher than the drainage capacity, inundating low-lying residential areas.
3. Impacts of urban flooding include disrupted daily life, damaged infrastructure, and decreased economic activity in affected areas. The document calls for improved flood management strategies to better mitigate urban flooding risks in Bangalore.
Enhancing post disaster recovery by optimal infrastructure capacity buildingeSAT Publishing House
This document discusses enhancing post-disaster recovery through optimal infrastructure capacity building. It presents a model to minimize the cost of meeting demand using auxiliary capacities when disaster damages infrastructure. The model uses genetic algorithms to select optimal capacity combinations. The document reviews how infrastructure provides vital services supporting recovery activities and discusses classifying infrastructure into six types. When disaster reduces infrastructure services, a gap forms between community demands and available support, hindering recovery. The proposed research aims to identify this gap and optimize capacity selection to fill it cost-effectively.
Effect of lintel and lintel band on the global performance of reinforced conc...eSAT Publishing House
This document analyzes the effect of lintels and lintel bands on the seismic performance of reinforced concrete masonry infilled frames through non-linear static pushover analysis. Four frame models are considered: a frame with a full masonry infill wall; a frame with a central opening but no lintel/band; a frame with a lintel above the opening; and a frame with a lintel band above the opening. The results show that the full infill wall model has 27% higher stiffness and 32% higher strength than the model with just an opening. Models with lintels or lintel bands have slightly higher strength and stiffness than the model with just an opening. The document concludes lintels and lintel
Wind damage to trees in the gitam university campus at visakhapatnam by cyclo...eSAT Publishing House
1) A cyclone with wind speeds of 175-200 kph caused massive damage to the green cover of Gitam University campus in Visakhapatnam, India. Thousands of trees were uprooted or damaged.
2) A study assessed different types of damage to trees from the cyclone, including defoliation, salt spray damage, damage to stems/branches, and uprooting. Certain tree species were more vulnerable than others.
3) The results of the study can help in selecting more wind-resistant tree species for future planting and reducing damage from future storms.
Wind damage to buildings, infrastrucuture and landscape elements along the be...eSAT Publishing House
1) A visual study was conducted to assess wind damage from Cyclone Hudhud along the 27km Visakha-Bheemli Beach road in Visakhapatnam, India.
2) Residential and commercial buildings suffered extensive roof damage, while glass facades on hotels and restaurants were shattered. Infrastructure like electricity poles and bus shelters were destroyed.
3) Landscape elements faced damage, including collapsed trees that damaged pavements, and debris in parks. The cyclone wiped out over half the city's green cover and caused beach erosion around protected areas.
1) The document reviews factors that influence the shear strength of reinforced concrete deep beams, including compressive strength of concrete, percentage of tension reinforcement, vertical and horizontal web reinforcement, aggregate interlock, shear span-to-depth ratio, loading distribution, side cover, and beam depth.
2) It finds that compressive strength of concrete, tension reinforcement percentage, and web reinforcement all increase shear strength, while shear strength decreases as shear span-to-depth ratio increases.
3) The distribution and amount of vertical and horizontal web reinforcement also affects shear strength, but closely spaced stirrups do not necessarily enhance capacity or performance.
Role of voluntary teams of professional engineers in dissater management – ex...eSAT Publishing House
1) A team of 17 professional engineers from various disciplines called the "Griha Seva" team volunteered after the 2001 Gujarat earthquake to provide technical assistance.
2) The team conducted site visits, assessments, testing and recommended retrofitting strategies for damaged structures in Bhuj and Ahmedabad. They were able to fully assess and retrofit 20 buildings in Ahmedabad.
3) Factors observed that exacerbated the earthquake's impacts included unplanned construction, non-engineered buildings, improper prior retrofitting, and defective materials and workmanship. The professional engineers' technical expertise was crucial for effective post-disaster management.
This document discusses risk analysis and environmental hazard management. It begins by defining risk, hazard, and toxicity. It then outlines the steps involved in hazard identification, including HAZID, HAZOP, and HAZAN. The document presents a case study of a hypothetical gas collecting station, identifying potential accidents and hazards. It discusses quantitative and qualitative approaches to risk analysis, including calculating a fire and explosion index. The document concludes by discussing hazard management strategies like preventative measures, control measures, fire protection, relief operations, and the importance of training personnel on safety.
Review study on performance of seismically tested repaired shear wallseSAT Publishing House
This document summarizes research on the performance of reinforced concrete shear walls that have been repaired after damage. It begins with an introduction to shear walls and their failure modes. The literature review then discusses the behavior of original shear walls as well as different repair techniques tested by other researchers, including conventional repair with new concrete, jacketing with steel plates or concrete, and use of fiber reinforced polymers. The document focuses on evaluating the strength retention of shear walls after being repaired with various methods.
Monitoring and assessment of air quality with reference to dust particles (pm...eSAT Publishing House
This document summarizes a study on monitoring and assessing air quality with respect to dust particles (PM10 and PM2.5) in the urban environment of Visakhapatnam, India. Sampling was conducted in residential, commercial, and industrial areas from October 2013 to August 2014. The average PM2.5 and PM10 concentrations were within limits in residential areas but moderate to high in commercial and industrial areas. Exceedance factor levels indicated moderate pollution for residential areas and moderate to high pollution for commercial and industrial areas. There is a need for management measures like improved public transport and green spaces to combat particulate air pollution in the study areas.
Low cost wireless sensor networks and smartphone applications for disaster ma...eSAT Publishing House
This document describes a low-cost wireless sensor network and smartphone application system for disaster management. The system uses an Arduino-based wireless sensor network comprising nodes with various sensors to monitor the environment. The sensor data is transmitted to a central gateway and then to the cloud for analysis. A smartphone app connected to the cloud can detect disasters from the sensor data and send real-time alerts to users to help with early evacuation. The system aims to provide low-cost localized disaster detection and warnings to improve safety.
Coastal zones – seismic vulnerability an analysis from east coast of indiaeSAT Publishing House
This document summarizes an analysis of seismic vulnerability along the east coast of India. It discusses the geotectonic setting of the region as a passive continental margin and reports some moderate seismic activity from offshore in recent decades. While seismic stability cannot be assumed given events like the 2004 tsunami, no major earthquakes have been recorded along this coast historically. The document calls for further study of active faults, neotectonics, and implementation of improved seismic building codes to mitigate vulnerability.
Can fracture mechanics predict damage due disaster of structureseSAT Publishing House
This document discusses how fracture mechanics can be used to better predict damage and failure of structures. It notes that current design codes are based on small-scale laboratory tests and do not account for size effects, which can lead to more brittle failures in larger structures. The document outlines how fracture mechanics considers factors like size effect, ductility, and minimum reinforcement that influence the strength and failure behavior of structures. It provides examples of how fracture mechanics has been applied to problems like evaluating shear strength in deep beams and investigating a failure of an oil platform structure. The document argues that fracture mechanics provides a more scientific basis for structural design compared to existing empirical code provisions.
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An experiental investigation of effect of cutting parameters and tool materials on tool life and productivity in turning of cylinder liners
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 360
AN EXPERIENTAL INVESTIGATION OF EFFECT OF CUTTING
PARAMETERS AND TOOL MATERIALS ON TOOL LIFE AND
PRODUCTIVITY IN TURNING OF CYLINDER LINERS
Prasanna P Kulkarni1
, Vinayak koppad2
, Hemanthkumar.K.S 3
1
Lecturer, Dept of Mech. Engg., Sri Taralabalu Jagadguru Institute of Technology Ranebennur, Karanataka, India
2
Lecturer, Dept of Mech. Engg., Sri Taralabalu Jagadguru Institute of Technology Ranebennur, Karanataka, India
3
Lecturer, Dept of Mech. Engg., Sri Taralabalu Jagadguru Institute of Technology Ranebennur, Karnataka, India
Abstract
The major needs of machining are high material removal rate, good work surface finish and low tool wear. Industries are hiring to
increase economical benefits by reducing the cost of production. These objectives can be achieved by using proper cutting tool
material and cutting parameters. This report presents comparisons of two different coated carbide inserts under different cutting
parameters used during machining of cylinder liners made up of grey cast iron. The comparison has been realized through the tool
life tests and productivity. The measurement has been carried out from rough boring operation at three cutting speed (Vc) and feed
rate (f). Depth of cut (doc) is kept constant at 1.5mm. Cutting tool used in this work is titanium nitride (TiN) coated carbide and
comparing with Multilayer coated tool is titanium nitride (TiN) + titanium carbo nitride (TiCN) + Aluminium oxide (Al2O3) coated
carbide inserts. The type of the insert is SNMG 120408. Cutting conditions used is speed (Vc) 100m/min, 125m/min, 150m/min. Feed
rate (f) 0.25mm/rev,0.3mm/rev,0.35mm/rev. Finally results of the present work determine the appropriate parameter for increasing
the tool life, and productivity.
Key words: Tool life, Coated tool material, Process parameters, Productivity.
------------------------------------------------------------------------------***------------------------------------------------------------------------------
1. INTRODUCTION
The cylinder liners usually made from Grey cast iron. Cast iron
has been used in large quantities for years because of desirable
properties as good cast ability, good machinability and low
cost. A wide variety of Gray Cast Iron is used in industries for
various applications. Machinability of Cast Iron is affected by
the amount of carbon [3]. Cast iron has been used in large
quantities for years because of desirable properties as good cast
ability, good machinability and low cost. This is brittle, weak
and is not malleable. A wide variety of Gray Cast Iron is used
in industries for various applications. Machinability of Cast
Iron is affected by the amount of carbon. It has excellent
machinability, good wear resistance, and high vibration
absorption. Grey iron is valued particularly for its ability to be
cast into complex shapes at relatively low cost. Thus, its
application includes: Sanitary wares, household appliances,
rolling mill and general machinery parts, ingot moulds,
cylinder blocks and heads for I.C. engines, frames for electric
motors, machine tool structures, etc.
Increasing the productivity and quality of the machine parts are
the main challenges of manufacturing industries. Modern
cutting tool allow cutting at high speeds, thus increasing the
volume of chips removed per value of unit time. The objective
of machining is to produce high quality product with minimum
cost. Development of tool material plays very vital role to
achieve this objective and to cope up with high speed cutting
(HSC). The purpose of development of cutting tool material
has different advantages such as reducing the manufacturing
cost and lead time, machining more difficult materials, moving
to unmanned machining operations, improving surface
integrity and achieving high metal removal rates [2]. The
advantage of high speed machining is not only to reduce
machining cost by increasing metal removal rate but also
yields good surface quality of machined parts [2].
The cost of replacing cutting tools is a major slice of the total
running cost of the manufacturing industries. It is therefore
desirable to have cutting tools that can be used for a long time
before being replaced. This can be achieved either by making
cutting tools from more wear resistant materials or through the
selection of machining conditions that will result in lower tool
wear. The use of cutting tools made of wear resistant materials
invariably increases the operating cost; a lower material
removal rate may result in lower productivity, making the final
products uncompetitive. The ideal situation would be one
where a desirable productivity is attained at an acceptable rate
of tool wear.
Carbides are the most prevalent tool materials, they are tough
and they can be used for machining using high feed rate, speed
and for difficult intermittent machining. Coated carbides
consist of a hard carbide base and coating which increases the
thermo-chemical stability (carbides, nitrides, oxides and their
combinations).
Carbide cutting tools are widely used in metal cutting industry
for the cutting of various hard materials such as alloy steels,
die steels, white cast iron and graphite cast iron. During
machining coated carbide tools are ensure higher wear
resistance, lower heat generation and lower cutting forces, thus
2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 361
enabling them to perform better at higher cutting conditions
than their uncoated counter parts. Coating is also used on
cutting tools to provide improved lubrication at the tool/chip
and tool/workpiece interface and to reduce friction, and
consequently reduce the temperature at cutting edge.
Quality of the machined component is an important index of
machinability for evaluating the productivity. Usually, the
cutting parameters are selected based on experience or a
handbook (Yang & Tarng, 1998) by engineer but it does not
yield the accurate results. Therefore, in turning process, it is
important task to select cutting parameters for achieving high
cutting performance, which greatly influences manufacturing
cost. An optimum selection of cutting conditions is extremely
important. In order to predict surface quality in advance, it is
important to develop theoretical models. Yang and Tarng
(1998) had used the Taguchi method to find the optimum
cutting parameters for turning operations as reported in paper
[2]. There have many studies concerning the effect of cutting
parameters and tool geometry on the cutting forces the
influence of machining parameters such as cutting speed, feed
rate, depth of cut for different materials[14]
The present work deals with experimental investigation on tool
life, surface roughness of grey cast iron using different coated
carbide inserts with different levels of process parameters.
Machining tests carried out on greaves cylinder blocks
produced from grey cast iron having areas involving grooves
(with interrupted surface) used in automotive industry. This
report presents the result of a Cycle time is considered as the
major aspect to be minimized to enhance the high productivity.
The influence of the machining parameters and tool material
on the tool life is also investigated and the optimum cutting
condition for minimizing the cycle time to enhance the
productivity is investigated.
2. EXPERIMENTAL DETAILS
In the present experimental test were performed on the cylinder
liners made by grey cast iron. Coated carbide inserts are used
as tool materials. Titanium nitride coated carbide and Titanium
nitride + Titanium carbonitride + Aluminium oxide coated
carbide are used as tool materials.
2.1 Work Material
Cylinder liners made from grey cast iron is used as work
material. Since it is most commonly used grade in the
automotive industries. The cylinder liners of size Ø80 x137mm
length were used for the present investigation. Fig. 1 shows the
cylinder blocks before machining and after machining. The
chemical composition of the material is shown in the Table 1.
Fig. 1: Work piece
Table -1. Chemical composition of grey cast iron
(Greaves cylinder)
2.2 Selection of Cutting Tool materials
The turning tests were conducted using coated cemented
carbide cutting tool with negative rake angle and 0.8 nose
radius. CVD coated Carbides with the specification SNMG
120508-GN (with an ISO designation), TiN coated (TT1300)
& TiN+TiCN+Al2O3 (Multilayer coated IC5010) inserts shown
in Fig.2a and Fig.2b. Tool holder which is specially used for
SNMG inserts for boring operation shown in Fig. 2c.
a b
Fig. 2 a) Multilayer (TiN+TiCN+Al2O3) coated carbide insert
b) TiN coated carbide insert
2.3 Machining Process
The experiments were performed on a Midas 8i CNC turning
(Lathe), Galaxy made, shown in Figure. 3a using grey cast iron
cylinder liner of length is 140mm and diameter of 80mm. All
tests were carried out in wet conditions. Two different cutting
tool materials and three different cutting speeds and Feed rates
(f) were employed throughout the experiments. Depth of cut
(doc) was kept fixed at 1.5 mm. Experimental were performed
under different cutting conditions shown in Table.2. The
ALLOYING
ELEMENTS
C Si Mn Cr Ph Su Cu
% wt
3.00
–
3.50
1.90
–
2.20
0.45
–
0.65
0.30
–
0.50
0.10 0.05 0.30
–
0.60
3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 362
effects of cutting speed (Vc), feed rate (f), and depth of cut
(doc) on tool life, surface roughness (Ra), and Cycle time and
number of components per edge were investigated for different
parameters.
Fig. 3: Machining process
2.4 Tool Life and Productivity plan
In this work tool life estimation involves a number of tests to
be carried out at various cutting conditions till the failure of
tool. Tool life was measured by considering number of
components produced before changing (corner burnt or
fracture) the cutting edge of the insert and total machined
length. Tool is measured in terms of minute. Productivity rate
were investigated by considering current existing condition in
industry, proposed planed condition. It was investigated by
varying three different speed and feed rates using two different
coated tools.
Tool life (T) = Machining length x No of components
produced / edge
Table- 2 Experimental cutting conditions
Factors Levels
Speed (Vc), m/min 100 125 150
Feed (f), mm/rev 0.25 0.3 0.35
3. RESULTS AND DISCUSSION
The results reported in the Table 3 and 4 were obtained as total
machined length of the cylinder block in order to determine the
tool life. Results were analyzed with different experiments
carried out on grey cast iron with different cutting parameters
for two different cutting tool materials.
3.1 Effect of Feed rates on Tool life
Fig. 4 shows, the comparative results of tool life for two
different tool materials. According to Fig. 4 it can be observe
that, performance of tool materials under different cutting
conditions. At high speed and feed rate performance of the TiN
coated carbide tool is less compare to the multilayer coated
tool.
Tool life estimation carried out at various cutting conditions till
the insert corner failure. To compare the performance of the
different tool materials under different cutting conditions,
machining process were carried out till the tool failure and
actual machined length. According to table it can be observed
that at speed 100m/min and feed 0.25mm/rev total machined
length is 5.48m. This is due to, less vibration, at lower speed
and feed rate which result better tool life but less material
removal rate it can be attributes that, low cutting speed
decreases chip curl radius increases chip thickness larger forces
and stresses to deform the material in the cutting zone [1]. As
in case of higher feed rate the tool life was decreased. It was
seen from the Figure at feed rate 0.35mm/rev, for all
corresponding speeds, decreased in tool life that is below
25min, machined length which was less than 3m. It can be
explain increase in feed rate, leads to decreases tool life, due
to high feed rate it increases vibration and heat, as a result
larger cutting forces and stresses developed on cutting edge
which results corner fracture (Broken) shown in fig 5b and 5c,
Cutting tools fail either by a gradual and progressive wearing
of its edge or due to chipping or plastic deformation [4].
Another parameter that is often ignored is tool vibration. It is
well known that vibration and chatter are important problems
those degrade the part quality and the tool performance [5].
Table-3 Tool life results for single layer coated
carbide tool
Sl.
No
Speed
(Vc),
m/min
Feed
(f ),
mm/rev
Depth
of cut
(doc),
mm
Machined
length(l),
m
Tool Corner failure
mode
1
100
0.25 1.5 5.48 Corner broken
2
100
0.3 1.5 2.8 Corner broken
3
100
0.35 1.5 1.37 Corner broken
4
125
0.25 1.5 5.48 Corner chip off
5
125
0.3 1.5 8.53 Corner burnt
6
125
0.35 1.5 3.69 Corner broken
7
150
0.25 1.5 8.22 Corner chip off
8
150
0.3 1.5 7.9 Corner burnt
9
150
0.35 1.5 1.64 Corner broken
4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 363
Table- 4 Tool life results for Multi layer coated carbide tool
Sl.
No
Speed
(Vc),
m/min
Feed
(f ),
mm/rev
Depth
of cut
(doc),
mm
Machined
length(l),
m
Tool Corner failure
mode
1
100
0.25 1.5 6.57 Corner broken
2
100
0.3 1.5 4.10 Corner broken
3
100
0.35 1.5 2.74 Corner broken
4
125
0.25 1.5 16.44 Corner burned
5
125
0.3 1.5 9.31 Corner broken
6
125
0.35 1.5 3.836 Corner broken
7
150
0.25 1.5 15.48 Corner burnt
8
150
0.3 1.5 12.05 Corner broken
9
150
0.35 1.5 5.40 Insert broken
It was observed from the table, increased in machining length
of 8.53m at feed rate of 0.3mm/rev and speed 125m/min, and
tool life is 69min. While machining grey cast iron, due to its
brittle property chip contact between tool edge and workpiece
is less which produces continuous chips. Tool life is directly
related to the work material, cutting tool material, and cutting
condition used while machining. As the feed rate increases to
0.35mm/rev, with all respective speeds tool life is decreases
due to rapid movement which causes the chattering and
rubbing action it generate high pressure that are exerted on the
chip-tool interface and tool-workpiece generate wear, also high
temperature at primary and secondary zone, it loses strength of
the cutting point and which results less tool life.
Fig. 4: Effect of Feed rates on tool life for Single layer coated
tool and Multilayer coated tool.
Table shows the experimental results of tool life by
considering actual machining length, where using multilayer
coated tool. It can be seen from the table Failure of the tool
after long interval time and total length machined is high when
compare to single layer coated tool. Development of new
cutting tool materials and availability of machine tools with
high rotational speeds have made it possible to increase
material removal rate. But at a high cutting speed tool wear
occurs more intensively and causes reduction in tool life [11].
It was observed from fig, general trends for higher tool life at
all three speeds at feed rate of 0.25mm/rev. At speed 125m/min
tool life is in increasing trend that is 140min, total machined
length is 16.44m shown in table. Also it can be observed tool
life is 112min at speed of 150m/min and machined length is
15.48m.This can be explained due to high thermal resistance
property, wear resistance property and temperature
withstanding capacity of multilayer coated tool [7, 8, 14].It is
evident that the longer tool life in case of multilayer coated
tool as compare to single layer coated tool, due its toughness
and lower cutting forces, thus enabling them to perform better
at higher cutting conditions [6, 7, 8].Also it can be as tools
with CVD – Ti ( C, N)/Al2O3/TiN coated carbide tools
indicate higher resistance to abrasive wear and they can be
recommended to roughing operation [9] . The wear initially
starts with faster rate caused by micro chipping at the sharp
cutting edge (edge failure), also intensive pressure and
dynamic loading on cutting edges which leads to tool fracture
(broken) shown in Fig 5d.
a
b
5. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 364
c
d
Fig. 5: Tool corner failure mode
3.2 Effect of Feed rates on Productivity
a
b
Fig. 6: Effect of Feed rates on Productivity
a. Single layer coated tool b. Multilayer coated tool
It can be seen from the fig 6a and fig 6b, effect of feed rates on
productivity. Increasing in the productivity rate with increasing
the feed rate and speed. As the feed increases, this leads to
increases the components per unit time. At high speed and feed
rate material removal rate is high with minimum cycle time.
According to experimental results shown in table it is clear
that, the productivity rate is in increasing trend at higher feed
rate and speed. It can be explained due to the decreasing in
cycle time or processing time leads to increases in the
productivity rate. In order to attaining this goal is to gain a
more productivity with less cycle time and good tool life.
According to Fig. 6b it can be observed that, compare to single
layer coated tool, productivity rate is in increasing trend where
using multilayer coated tool. At high feed rate and speed,
components per shift is in the range of 170 to 180 no. This can
be explained that, the properties like high wear resistance and
toughness of multi layer coated tool. Some time tool life is also
factor which effect on productivity. Tool changing time which
leads to the less productivity. According to results, tool
changing time is less in case of multilayer coated tool compare
to single layer coated tool, due to the failure of tool is after
long period of time. Thus the purpose of development of
cutting tool material has different advantages such as reducing
the manufacturing cost and lead time, machining more difficult
materials, moving to unmanned machining operations,
improving surface integrity and achieving high metal removal
rates [2].
According to productivity calculation given below, it was
evident that percentage of improvement in production rate by
considering current existing condition in industry, proposed
condition. It was investigated by varying three different speed
and feed rates using two different coated tools. Finally it was
clear that, Modern cutting tools allow cutting at high speeds,
thus increasing the volume of chips removed per unit time and
this objective requires better management of the machining
system corresponding to cutting tool-machine-workpiece
6. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 365
combination to go towards more rapid metal removal rate.
Exploring higher cutting speed depends to a greater extend on
the cutting tool materials [2]. Development of tool material
plays very vital role to achieve this objective and to cope up
with high speed cutting [2].
3.3 Productivity Calculation
In present work productivity is calculated by considering
overall operation time taken during boring of cylinder block.
Also the percentages of productivity were determined by
considering the current existing production rate per shift with
corresponding cutting conditions. Present existing condition is
considered as reference range (100%). By changing the cutting
conditions it can be obtained the high productivity.
3.3.1 Steps for calculating the productivity
1. Initial diameter of job = Ø80mm
2. Final diameter of job = Ø85.5mm
3. Length of the job L = 137mm
4. Total machining length = 137+3 = 140mm (3mm clearance)
5. Total no of cuts = 2 cuts
6. First cut = 1.5mm
7. Second cut = 1.25mm
a)Rough boring operation (CNC)
Speed (Vc) = 100m/min, 125m/min, 150 m/min
Feed rate (f) = 0.25mm/rev, 0.3mm/rev, 0.35 mm/rev
Depth of cut (doc) = 1.5 mm (constant)
b) Finish boring operation (CNC)
Speed (Vc) = 125m/min
Feed (f) = 0.22mm/rev
Depth of cut (doc) = 1.25mm
Total cycle time = Tm1+Tm2+Tc+loading & unloading time
Tm1 = Rough boring operation time
Tm2 = Finish boring time
Tc = Tool changing time =10sec, and
Loading & unloading time = 10sec
b) Finish boring operation (Constant)
Speed (Vc) = 125m/min, Feed (f) = 0.22mm/rev,
DOC (doc) = 1.25mm
Machining time (Tm2) = 1m 25sec (85sec)
I. Rough boring operation time calculation
Current existing conditions
Speed (Vc) = 125m/min, Feed (f) = 0.25mm/rev,
Depth of cut (doc) = 1.5mm
Machining time = 1m15sec (75 sec)
Total time = Tm1+Tm2+Tc+loading & unloading time
= 75+85+10+10:- 180 sec (3min)
No of components per hour = 20no’s.
No of components per shift = 20 x 7 hr = 140no’s.
3.3.2 Percentage of productivity improvement
Percentage of improvement in productivity is calculated
as given below
Productivity percentage (%) is
Proposed production / Current Existing production
Current existing production = 140.no/ shift
(At Vc = 125m/min, f = 0.3mmrev)
Proposed production = 168 no/shift
(Cocidered Vc = 125m/min, f = 0.3mmrev)
Rate of improvement
Proposed production – Current existing production
168 – 140= 28 no’s.
Percentage of improvement in productivity
28 *100/140
20%
Table-5 Optimized parameters for different tool materials
Sl.
No
Speed
(Vc),
m/min
Feed
(f ),
mm/rev
TCC (Tool 1) MLC(Tool 2)
Tool
life (T),
min
Productivity
(7hr)
Tool
life
(T),
min
Productivity
(7hr)
1
100
0.25 61 126 72 126
2
100
0.3 26 140 38 140
3
100
0.35 11 147 22 147
4
125
0.25 50 140 140 148
5
125
0.3 69 168 56 175
6
125
0.35 24 175 19 182
7
150
0.25 65 154 112 158
8
150
0.3 52 165 69 175
9
150
0.35 8 176 23 189
The summarized values for the single layer coated tool
material are as depicted in Table.5. From the table it can be
observed that, the combination of tool life and the
productivity are at their optimum rates.
It can be observed from table 5 that, the appropriate
parameters in order to obtain better tool life, productivity, and
minimum surface roughness. The results of the appropriate
parameters are presented in the following paragraphs.
7. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 03 Issue: 01 | Jan-2014, Available @ http://www.ijret.org 366
As the speed increases, the material removal rate also
increases. At high speed, the surface roughness is minimum
with low feed rate. According to results it can be observe that,
at speed 150m/min and feed rate 0.25mm/rev, increasing in
tool life and productivity rate compare to currant existing
condition. On other hand surface roughness, it can be obtained
within the recommended range (4µm). In order to obtain the
better tool life and productivity appropriate cutting conditions
for TiN coated carbide tool is: Speed 125m/min and feed
0.3mm/rev and speed 150m/min, feed 0.3mm/rev.
The summarized values for the multi layer coated tool material
are as depicted in Table.5. From the table it can be observed
that, the combination of tool life and the productivity are at
their optimum rates.
According to the experimental results, it was clear that, for the
higher speed values, the tool life and productivity is high.
Whereas the surface roughness is also obtained within the
recommended range. At speed 150m/min and feed rate of
0.25mm/rev and 0.3mm/rev, all three existing results are in
increasing trend as compare to TiN coated tool. It can be see
least surface roughness of 1.94µm. with better tool life and
productivity rate. This is due to coated carbide tools or
multilayer coated carbide tools ensure higher wear resistance,
lower heat generation and lower cutting forces, thus enabling
them to perform better at higher cutting conditions compared
to uncoated counter parts [6]. Based on the experimental
results it was evident that the performance of the multilayer
coated tool is better as compare to single layer coated tool.
Performance Multilayer coated tool is better in order to tool
life and productivity as compare to single layer coated tool and
uncoated tool .This indicates that the titanium nitride (TiN)
coating on alumina (Al2O3) + titanium carbonitride (TiCN)
multilayer-coated tools helps improving the quality of
machined surface[6,12].
4. CONCLUSIONS
In this study based on the tool materials and cutting parameters
following conclusions were presented.
.
With the help of different experimental work, effect of process
parameters on the tool life and productivity has been
investigated. The optimal machining conditions have been
presented in the following points.
1. The multilayer coating TiN-TiCN-Al2O3 perform
superior compare to single layer coated tool, they can
be recommended to machine grey cast iron cylinder
blocks.
2. Increasing the feed rate of 0.35mm/rev increase the
tool failure with all three speeds with two coated tools.
3. At high cutting speed and feed rate tool life is
maximum from multilayer coated tool compare to
TiN coated tool.
4. Productivity rate is also increased with increasing speed
and feed rate with less tool wear with multilayer coated
tool.
5. Optimized parameter for high productivity and better
tool life is at speed 125m/min, 150 m/min and feed
0.25mm/rev, 0.3mm/rev obtained.
6. Performance of multilayer coated tool is superior compare
to TiN coated tool in terms of tool life and productivity.
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BIOGRAPHIES
Prasanna.P.Kulkarni
Presently working as lecturer
From past 2 years in Mechanical
Engineering Department. Also having
1 year experience in tooling industries.
Hemanth kumar K.S
Presently working as lecturer from past 3years
in Mechanical engineering Department.Also
having 6months experience in tooling
industry.
Vinayak koppad
Presently working as lecturer
from past 3years in
Mechanical engineering
Department.