Uncoated Carbide Inserts Research Articles

Prediction of Surface Roughness after Turning of Duplex Stainless Steel (DSS)

Feed Forward Back Propagation artificial neural network (ANN) model utilizing the MATLAB Neural Network Toolbox is designed for the prediction of surface roughness of Duplex Stainless Steel during orthogonal turning with uncoated carbide insert tool. Turning experiments were performed at various process conditions (feed rate, cutting speed, and cutting depth). Utilizing the Taguchi experimental design method, an optimum ANN architecture with the Levenberg-Marquardt training algorithm was obtained. Parametric research was performed with the optimized ANN architecture to report the impact of every turning parameter on the roughness of the surface. The results suggested that machining at a cutting speed of 355 rpm with a feed rate of 0.07 mm/rev and a depth of cut 0.4 mm was found to achieve lower surface roughness with, an increase in the cutting speed and feed rate with the increases of the surface roughness. In addition, an increase in the depth of cut was found to reduces the surface roughness. The outcome of this study showed that ANN is a versatile tool for prediction of surface roughness and may be easily extended with greater confidence to various metal cutting processes.

Machinability Investigations on Aerospace Custom 450 Alloy Using TiAlN/TiCN, TiCN/TiAlN Coated and Uncoated Carbide Tools

In this present research, the machinability studies of TiAlN/TiCN, TiCN/TiAlN coated and uncoated inserts were investigated on machining custom 450 alloy. The machining input parameters such as feed rate (f), cutting speed (V) and depth of cut (d) are set using orthogonal array. The machining output parameters such as surface roughness, tool wear and cutting forces were studied for its parametric contribution and it was analyzed using Analysis of Variance (ANOVA). Further, the tool wear obtained was studied using scanning electron microscopic images and energy dispersive spectroscopy analysis was conducted to check the addition of work material elements to the coated tool surface. The results show that, the feed rate is the most contributing factor in deciding resultant forces, surface roughness and tool wear respectively. TiAlN/TiCN coated carbide tool has obtained improved machinability, when compared to TiCN/TiAlN coated carbide and uncoated carbide inserts. To obtain one optimal level for all three responses of three types of tools, multi criteria decision making approach, named utility concept approach is selected. Based on the MCDM analysis, it is found that trial number 4 gives better experimental output of improved surface integrity, lower resultant force and less tool wear for all types of tools.

Machining process parameters optimization of Aluminium Alloy AA6262 T6 for CNC Turning by Grey Relational Analysis

This research paper is based on the optimization for machining parameter of turning process of CNC M/C tool on aluminium alloy with the help of grey relation analysis. The parameters is found out the experiments perform on aluminium alloy AA6262T6. Machining operation is performed under dry cutting condition by uncoated carbide insert tool. In this research work operation parameters like feed, speed and depth of cut is optimized with output of material removal rate and surface roughness. In the present work, grey relation grade is used as a tool for optimization technique. The result is obtained by grey relation grade find out through grey relation analysis. The experiment outcomes are clear that the response in turning process can be increase efficiency from this fresh approach. To validate the test result, the confirmation test is performed. Prediction of GRA shows the noteworthy increment of 16.629 (14.55 %) in Material Removal Rate (MRR) and a noteworthy reduction of 0.148 (8.9%) in Surface Roughness.

Adhesion area estimation using backscatter image gray level masking of uncoated tungsten carbide tools

Machining tribology research reveals that adhesion of the workpiece material to the cutting tool is an important aspect that governs a number of physical parameters within the tool-chip interface. Adhesion is especially a concern during machining difficult-to-cut materials such as nickel-based alloys. Adhesion may cause tool wear that leads to premature tool failure, or it may trigger other wear modes, hindering machinability and reducing product quality. Many researchers are investigating adhesion fundamentals, adhesion quantification being an indispensable tool. The research suggests strategies to reduce adhesion's undesirable effects. However, when many experimental trials are required, time-consuming adhesion quantification may cause a bottleneck. This study proposes an efficient adhesion area quantification method using image processing of discrete gray intensities on backscatter images of uncoated tungsten carbide inserts, revealed by scanning inserts through an electron microscope. The obtained images are analyzed statistically from their gray-level intensity distribution. A recognizable gray-level range, located around a peak in the histogram, corresponds to adhered material and can easily be distinguished from the background tool material. Hence, adhesion pixels are masked and counted in a statistically controlled manner. The total adhesion area is subsequently quantified by summing the total number of adhesion pixel areas. This method is applied to quantify the resulting adhesion for a variation of the cutting speed, based on a number of orthogonal machining trials carried out on nickel-based superalloy NiCr19Fe19Nb5Mo3 (2.4668), using uncoated tungsten carbide inserts. K-means clustering algorithm is applied for image segmentation, and elemental mapping is obtained by energy dispersive x-ray spectroscopy; both are used to evaluate the effectiveness of the proposed method.

Effect of physical vapour deposition coated and uncoated carbide tools in turning aluminium alloy-AA6063

The effect of the machining process has been expanding step by step to fulfil the needs of the current mechanical insurgency. The current enterprises are zeroing in streamlining materials wastage and the machine tools. In this work, the principle center is around enhancing the cutting conditions and the surface nature of workpiece material while machining aluminium alloy AA6063 utilizing physical vapour deposition (PVD) carbide inserts and uncoated carbide inserts. The examinations were done based on L9 orthogonal array utilizing taguchi method. Additionally, the examination was finished utilizing analysis of variance (ANOVA) and the combined effect of parameters are analysed utilizing multiple regression (MR) examination. The test results were contrasted and anticipated qualities and the ideal tests were gotten independently with TiCN coating PVD coated and uncoated carbide inserts. From the outcomes acquired by examination of analysis of variance, it was observed that the influence of feed (84%) is more on surface roughness compared to speed (2%) and depth of cut (13%), the depth of cut influenced (79%) more on cutting force compared to speed 8% and feed (5%), the speed (68%) influenced more on temperature compared to feed (6%) and depth of cut (21%). It was seen that machining with PVD coated carbide inserts delivered 11% better surface roughness, 10% less power and 12% lower temperature contrasted with uncoated carbide inserts during the machining of aluminium alloy AA6063. In light of the conclusive outcomes got, the utilization of PVD coated carbide inserts can give better machining execution of AA6063 contrast with uncoated carbide inserts.

Process design for minimization of resultant cuttting forces during the machining of heavy-duty piston

In this study, machining performance a series of commercially available uncoated carbide inserts with different depth of cut investigated during plunging of aluminum alloy (LM-13) and NI-alloy (MPL-251) of heavy-duty piston. For comparison, different depth of cut with same angle was also tested under the same cutting conditions. Direction of plunging machining operation is perpendicular to the axis of the piston which will be X- direction. In present work Taguchi analysis using ANOVA for 3 parameter, 3 level experimentation - full factorial (l27 array) were done with output response variables like resultant cutting forces, mean surface roughness (Ra), maximum surface roughness (Rt). Main effects of factors and their interactions were studied and multiple optimizations of the responses were analyzed by grey relational analysis using Taguchi methods to find the best optimal setting of parameter levels. The confirmation tests were carried out to reveal the accuracy of the best setting of parameter levels. Through analysis of variance (ANOVA), it was found that selection of depth of cut tool has greater influence on cutting surface roughness, selection of feed and cutting speed has greater influence on resultant cutting forces. Whereas selection of cutting speed, feed rate and depth of cut has greater influence on the cutting forces. Grey relational analysis using Taguchi techniques gives the best optimal results by setting cutting parameters at lower level of 300 m/min, feed at lower level of 0.04 mm/rev and depth of cut 6 mm at higher level for better output. It was also found that the cutting speed and feed rate tool has the strongest effect on the multi-performance characteristics among the other machining parameters.This paper describes Grey relational analysis. Taguchi techniques gives the best optimal results by setting cutting parameters at lower level of 300 m/min, feed at lower level of 0.04 mm/rev and depth of cut 6 mm at higher level for better output. It was also found that the cutting speed and feed rate tool has the strongest effect on the multi-performance characteristics among the other machining parameters.

Experimental investigation of surface roughness and cutting force during machining of SS43100 by using coated and uncoated carbide inserts

Machining processes are the accurate metal removal processes for shaping components in the manufacturing industry. The main challenges of the manufacturing industry are to increase productivity and quality. Manufacturing industries are trying to reduce the cost of machined parts which are manufactured by different machined methods. Machining hard metals is a challenging task. In the presented research work machining parameters were investigated for machining of SS43100 by using coated and uncoated carbide tool inserts. Carbide tool inserts were coated by Ti16Zr using the PVD method of coating. Experiments were performed during the turning operation of SS43100 by coated and uncoated tool inserts. Cutting speed range were 150r.p.m, 250 r.p.m., 350 r.p.m., feed were 0.085 mm/rev, 0.095 mm/rev, 0.1 mm/rev. and depth of cut was 0.1 mm, 0.15 mm, and 0.2 mm selected as controlling factors. Surface roughness and cutting force were selected as response factors. Digital lathe tool dynamometer was used for cutting force measurement and ITI surface tester RS232 was used for surface roughness measurement. In the experimental study and analysis of output response parameters, Taghuchi L9 orthogonal array model has used The results obtained were optimized using the Taghuchi technique for cutting forces and surface roughness. The Taghuchi technique was performed for combinations of each input variable in linear fit model multivariate analytics. Experimental results were compared and models established supported by evidence.

Adhesion of Inconel 718 on Uncoated Tungsten Carbide Inserts in Interrupted Orthogonal Machining under MQL

Nickel-base super-alloys such as Inconel 718 are used for demanding applications in the industry. Their superior corrosion resistance and mechanical properties, especially under high heat and pressure, make them very attractive for highly stressed components. In contrast, their low thermal conductivity, work hardening tendency and high strength impose challenges for machining. In particular, occurring adhesion of the workpiece material on tungsten carbide (WC) inserts and tools is common hindering their life. In order to counteract this undesirable effect, cutting fluids are usually implemented. However, due to increased awareness of cutting fluids negative impact on the operator’s health and the environment, minimum quantity lubrication (MQL) is getting more attention among researchers and in the industry. In this study, the adhesion on the rake face of uncoated WC inserts under the application of MQL is observed. Inconel 718 workpieces prepared for orthogonal cutting trials are interrupted at variable intervals to allow more access for MQL to reach chip-tool interface. Mechanical load, coefficient of friction, adhesion area and chip-tool contact length on the rake face are investigated. It has been observed that interrupted machining can positively influence adhesion area and chip-tool contact length.

Study of machinability in heat-assisted machining of nickel-base alloy

In the present work, a hot turning is performed on Inconel 718 to determine the effect of heating on material removal rate, forces, power consumption, tool life, and specific cutting energy. The cutting tests are carried out using uncoated carbide insert at varying machining conditions, for both room temperature and 600 °C temperature. The results show that there was an increase in tool life, material removal rate, and reduction of forces, specific cutting energy and power consumption in hot conditions compared to room temperature machining conditions.

Turning experiment of Ti-6Al-4V by using uncoated carbide insert

Titanium alloy Ti-6Al-4V is widely being used in the blades, discs, rings, airframes, fasteners, components, vessels, cases, hubs, forgings and biomedical implants. Nevertheless, the properties of titanium alloys which are low thermal conductivity, low modulus of elasticity and high chemical activity cause it very difficult to machine. Excessive elevated temperature due to low thermal conductivity of these alloys make it favorable for tool wear. In this paper, an experiment using orthogonal array L4 is conducted to explore the effect of cutting parameters e.g. cutting speed, depth of cut and feed rate in terms of surface roughness and tool wear. The cutting tool uncoated carbide is used in performing orthogonal cutting of Ti-6Al-4V in this study. It is found low cutting speed, feed rate and high depth of cut is favourable in producing good Ra and minimum flank wear.

Taguchi based Optimization of Coated and Uncoated Tool Insert for Turning Ti6Al4V using Grey Relation Analysis

The titanium alloy Ti6Al4V has been widely used due to its high strength to weight ratio. The titanium machinability is very troublesome because of its hardness, low elastic modulus at elevated temperature and thermal conductivity, and has high chemical affinity. In this paper we have studied surface roughness, material removal rate for CNC Turning of Ti6Al4Vby comparing it with two inserts, one is tungsten carbide coated having a coating of TiAlN and the other is the uncoated tungsten carbide inserts by varying the input parameters such as cutting Speed, feed rate, depth of cut (DOC). These experiments were based on Taguchi’s orthogonal array for three factor and three levels and experiments has been conducted based on L27 orthogonal array for turning operation on computer numerical control machine. Further optimization is done based on multi response optimization-Grey Relational Approach (GRA) to get the optimized parameter for the maximum Material Removal Rate (MRR) and minimum Surface Roughness (Ra). However the surface roughness of the coated insert was found to minimal than the uncoated insert in which the coating just improves the life of the cutting tool.

Numerical contribution to segmented chip effect on residual stress distribution in orthogonal cutting of Inconel718

Segmented chip morphology has a significant influence on distribution of residual stress and surface topography on machined surface in machining difficult-to-cut materials. In this paper, Coupled Eulerian and Lagrangian (CEL) model is employed to investigate the effect of segmented chip on surface integrity (residual stress distribution and surface topography) in orthogonal machining of Inconel718 with uncoated carbide inserts. A mesh sensitivity study of chip morphology and residual stress distribution is performed by developing the following three different grid resolutions: coarse (mesh size 35 μm), medium (10 μm) and fine (5 μm). Comparing with the experimental results, it is clear that the numerical model presents reasonable results, including the chip morphology, temperature distribution, cutting forces, residual stress profile and surface fluctuation period. As for the generated surface integrity, a waved surface and cyclic residual stress distribution are found with the segmented chip due to the periodical mechanical and thermal loadings acting on the machined surface. Furthermore, the formation of single chip segment is investigated in-depth to explain the residual stress distribution generation.

Influence of cutting speed on dry machinability of AISI 304 stainless steel

The present work deals with the machining performance of AISI304 stainless steel under a dry machining environment. Machining operations are performed with varying cutting speeds using uncoated tungsten carbide insert. The average tool-tip temperature, machining induced cutting forces and the flank wear progression depth were analyzed with regard to the cutting speeds. In addition, different wear mechanisms for the worn-out cutting inserts are studied. The work also extends study of chip macro-morphology. The maximum value of tangential component of cutting force (∼167 N) is attained at V = 190 m/min. Moreover, at V = 190 m/min, tool-tip temperature is recorded as 88.9 °C; which appears the maximum for all cutting speeds tested. At V = 247 m/min, depth of flank wear assumes the highest value (∼71.9 µm).

Effects of Cutting Speed on MQL Machining Performance of AISI 304 Stainless Steel Using Uncoated Carbide Insert: Application Potential of Coconut Oil and Rice Bran Oil as Cutting Fluids

In metal machining, minimum quantity lubrication (MQL) refers to supply of an optimal amount of cutting fluid into tool-work interfacial region. As compared to traditional dry machining, machining process executed under MQL has several advantages. Properties of cutting fluid play important role toward machining performance. In the present work, application potential of rice bran oil is compared with coconut oil in the context of MQL machining of AISI 304 stainless steel. Cutting force magnitude, approximate tool-tip temperature, flank wear depth, etc., are studied as machining performance indicators. In addition, different tool wear mechanisms, chip morphology, and surface roughness of the machined work part are studied in detail. It is experienced that MQL (rice bran oil) outperforms MQL (coconut oil). MQL (rice bran oil) exhibits lower cutting force, lesser tool-tip temperature, reduced extent of tool wear, and better machined surface finish than dry as well as MQL (coconut oil) machining.

Performance Evaluation of Cryogenic Treated and Untreated Carbide Inserts during Machining of AISI 304 Steel

The cutting tool in the machining process plays an important role as it acts on the working material. There are a few methodologies have been persued to improve tool life, for example traditional cooling, single layer coating, multilayer coating, heat treatment process, nitrogen cooling and latest being the cryogenic treatment which reported a significant improvement in cutting tool life, chip morphology, reduction in heat generation. Hence, the cryogenic treatment is emerged as the sustainable machining process. This paper presents machining of AISI 304 steel using both cryogenic treated (CT) and untreated (UT) cutting tool insert. The commercially available uncoated carbide insert has been cryogenically treated at -196°C for 24 hours soaking period. The machining test has been conducted under four different cutting speeds. The material characterization of cutting insert is studied by using scanning electron microscopy (SEM), hardness test, and microscopic image analysis has been carried out before and after cryogenic treatment. The cutting tool performance is assessed in terms of of wear, cutting temperature, chip morphology, surface roughness under the influence of cryogenic machining and the results are contrast with UT one. The exploratory findings reveals that the deep cryogenic treatment (DCT) with 24 hours soaking period, performed better wear resistance and improved surface roughness of the cutting tool. Also considerable reduction in the flank wear, crater wear, cutting temperature is obtained and found improved chip morphology.

Wear of WC inserts textured by shot peening and electrical discharge machining

In this paper, the wear and cutting performance of uncoated cemented tungsten carbide (WC) inserts textured by shot peening (SP) and electrical discharge machining (EDM) was compared to examine the hypothesis that texturing processes involving surface re-melting are inferior to processes based on surface plastic deformation. Lubricated orthogonal tube turning experiments demonstrated that the WC inserts with irregular rake face surface texture exhibit either longer or shorter tool lives than untreated inserts depending on the combination of surface roughness and residual stress. Higher roughness and compressive residual stress produced by SP led to increase in wear resistance and tool life by about 30% through reduction of the tool-chip contact area and the apparent tool-chip friction. Tensile surface residual stresses generated by EDM resulted in chipping of the tool and, hence, shorter tool life by more than 80% even when cutting forces were lowered. Moving the treated area away from the cutting edge neutralized the effect of texture on tool life. Based on the test results, surface modification of WC inserts through SP yielded better tool life performance than surface modification through EDM.

Hybrid Taguchi-GRA-PCA approach for multi-response optimisation of turning process parameters under HPC condition

Process parameter optimisation is important in manufacturing. An effective and efficient manufacturing process offers low temperature, low force and high material removal rate without compromising the product quality. An experimental investigation designed by Taguchi's orthogonal array for turning AISI 1060 steel by uncoated carbide insert under high-pressure coolant (HPC) condition. Since all these aforementioned responses are mutually conflicting, simultaneous multi-response optimisation is required to acquire a trade-off among the responses. Standalone Taguchi method is not sufficient for multi-response optimisation. Grey relational analysis (GRA) can be coupled with Taguchi method to overcome this complexity, where overall process performance index grey relational grade (GRG) is calculated and used for the optimisation of the process by using Taguchi's S/N ratio. Principal component analysis (PCA) can be utilised to determine the individual importance of each response, which facilitate accurate computation of overall GRG. The effect of process parameters on GRG was analysed using analysis of variance (ANOVA). Validation by confirmation test was also performed.

Optimization of hot turning parameters using principal component analysis method

Abstract With a specific goal to develop an extension among quality and efficiency, the present study highlights the optimization of turning cutting parameters to provide less power, higher surface finish and high chip reduction coefficient. In the present investigation, cutting parameters have been optimized in the hot turning of Inconel 625 with uncoated carbide insert. The workpiece has been heated up to 600˚C using flame heating method and tests are performed with different cutting parameters. The power, surface finish and chip reduction coefficient have been identified as responses and directly related to productivity. The multi-response optimization method has been carried out using principal component analysis with the Taguchi approach to fulfil simultaneously. From the analysis, cutting speed has the most influence parameter affects the responses

Multi-objective optimisation of process parameters in turning of Al6061 alloys using DEFORM-3D

Turning operation is one of the most widely used machining processes in manufacturing industries wherein optimisation of process parameters is the most critical aspect within the operational constraints. In this paper, finite element simulations have been carried out for dry turning of Al6061 alloy with uncoated tungsten carbide inserts to predict the performance of machining. Thus, the effect of process parameters such as cutting speed, feed rate and depth of cut on response variables such as cutting temperature, cutting energy, effective stress, material removal rate and tool life have been studied by employing Taguchi L25 orthogonal array. Grey relational analysis has been further used to convert multi responses parameters to a single response for optimising the process parameters using particle swarm optimisation. The results of the study indicated that the cutting speed of 40 m/min, feed rate of 0.04 mm/rev and 0.5 mm depth of cut provides better machining performance based on the application of simulation approach leading to time saving and efficient utilisation of resources.

Multi-objective optimisation of process parameters in turning of Al6061 alloys using DEFORM-3D

Turning operation is one of the most widely used machining processes in manufacturing industries wherein optimisation of process parameters is the most critical aspect within the operational constraints. In this paper, finite element simulations have been carried out for dry turning of Al6061 alloy with uncoated tungsten carbide inserts to predict the performance of machining. Thus, the effect of process parameters such as cutting speed, feed rate and depth of cut on response variables such as cutting temperature, cutting energy, effective stress, material removal rate and tool life have been studied by employing Taguchi L25 orthogonal array. Grey relational analysis has been further used to convert multi responses parameters to a single response for optimising the process parameters using particle swarm optimisation. The results of the study indicated that the cutting speed of 40 m/min, feed rate of 0.04 mm/rev and 0.5 mm depth of cut provides better machining performance based on the application of simulation approach leading to time saving and efficient utilisation of resources.