Work-hardening Materials Research Articles

Crystal-plasticity modelling of the yield surfaces and anelasticity in the elastoplastic transition of metals

The paper presents a full-field crystal-plasticity computational investigation of 10με small-strain-offset yield surfaces with pointed vertexes that are seen in the elastoplastic transition of pre-strained polycrystal metals. It is concluded that the shape of these yield surfaces obtained with a full-field spectral solver compares reasonably well with calculated ones by a simple aggregate Taylor model. The influence of material strength, work hardening, and texture are discussed. An assessment is made of the origin of anelasticity and Bauschinger effects at small strains, considering two mechanisms. Firstly, there is a built-in composite effect in crystal elastoplastic simulations due to the mixture of elastically and plastically loaded grains. Secondly, kinematic hardening of reverse slip systems will contribute to the Bauschinger effect. Based on analyses of the computed selected cases and comparison to previously published measurements, it is concluded that both mechanisms are important.

Influence of Pilot Hole and Work Material Hardness on Thread Milling with a Wireless Holder System

Influence of Pilot Hole and Work Material Hardness on Thread Milling with a Wireless Holder System

Study on the High Temperature Tensile Properties and Strengthening Mechanism of Nitrogen Containing Nickel‐Based Deposited Metals

This article investigates the tensile properties and strengthening mechanism of nitrogen‐containing nickel‐based flux cored welding wire deposited metal from room temperature to 900 °C. The results showed that the high‐temperature strength of the deposited metal increased with the addition of Tungsten and Nitrogen. When the temperature reaches 700 °C, M23C6 carbides begin to decompose. The alloying elements dissolve back into the matrix, and the solid solution strengthening effect minimizes the plasticity of the alloy. More carbonitrides are precipitated within the crystal with temperature. During high‐temperature deformation, carbonitrides fractures at the interface with the substrate due to difficulty in coordinating deformation. Therefore, the crack source formed greatly reduces the strength of the material. In addition, the stacking faults present in the low‐temperature zone have a significant impact on the work hardening of materials. The main deformation mechanism is the unit dislocation a/2 < 110> cutting precipitation phase. It can be observed that the dislocation cutting precipitation mechanism system has transformed into a dislocation bypassing precipitation mechanism system at intermediate. Finally, the anomalous yield strength (YS) and intermediate temperature brittleness phenomenon are reasonably explained. The main deformation mechanism gradually transforms into dislocation slip and climbing with temperature.

Elucidating the dual effect of vanadium microalloying on hot deformation behavior of high nitrogen martensitic stainless steel

Precipitates always have a complex effect on the hot work hardening and recrystallization softening of materials. In this work, the dual effect of V-microalloying on hot deformation behavior and microstructure evolution of high nitrogen martensitic stainless steel (HNMSS) was investigated by hot compression experiments, modeling study and microstructure characterization. The results showed that V-microalloying enhanced the flow stresses and activation energy of 0.2V steel due to the fine grain strengthening effect and the blocking effect of dynamic precipitation on dislocation movement and grain boundary migration. On the other hand, the recrystallization model and deformed microstructure indicated the more intense dynamic recrystallization (DRX) softening effect in 0.2V steel, inducing the faster decrease of flow stress after the peak stress. V-microalloying promoted the dynamic precipitation of HNMSS during hot deformation, which reduced the size and increased the number of precipitates in 0.2V steel. The fine precipitates hindered dislocation movement, promoted dislocation accumulation and entanglement, formed a particle deformation zone (PDZ) with high dislocation density and large orientation gradient, and then induced the occurrence of particle-stimulated nucleation (PSN). In addition, the dislocation cells evolved from dislocation entanglement were also favorable nucleation sites for DRX.

Proposal of new crack-tip-opening-displacement as a mechanical driving force of elastic-plastic fracture mechanics

In this study, the current status of linear and nonlinear fracture mechanics was surveyed, and the conditions required for elastic–plastic fracture mechanics (EPFM) as the next step of fracture mechanics were listed. Then, the imaginary crack tip opening displacement (I-CTOD), expressed by the integral of the plastic strain in a two-dimensional plastic zone, was proposed as a driving force of EPFM. Elastic-plastic FEMs of cracked solids in various work-hardened materials were performed under both the plane stress and plane strain states to understand the singular field characteristics of elastic and plastic strains near a crack tip. The I-CTOD was found to represent the intensity of the plastic strain singular field, the elastic strain singular field, and the imaginary plastic deformation field near the crack tip in elastic–plastic solids under both the plane stress and plane strain states. This I-CTOD is promising as a mechanical driving force parameter of EPFM because the analyzable and visualizable characteristics of the behavior and its clear relationship to actual material behavior make it easy to develop prediction methods for the actual crack behavior.

Investigation on the transient rolling contact behaviour of corrugated rail considering material work hardening

The process of work hardening in the corrugation zone of the steel rail results in an uneven distribution of hardness, with higher hardness in the corrugation troughs and lower hardness in the corrugation crests. To study the influence of hardness on the rolling contact behavior of the wheel-rail at corrugation zone, a three-dimensional wheel-rail transient rolling contact finite element model is established based on the measured corrugation and hardness distribution of the rail to reveal the influence of the non-uniform distribution of hardness at corrugation zone on the wheel-rail contact state and the wear and fatigue of the rail surface. The results indicate that: (1) work hardening in the corrugation zone leads to an increase in equivalent stress and strain within the contact patch between the wheel and rail. However, due to the increase in yield strength, plastic deformation and residual strain are somewhat reduced; (2) The uneven distribution of hardness in the corrugation zone results in an elevation of longitudinal shear strain between the wheel and rail, which may initiate tangential fatigue cracks and spalling of the steel rail surface; (3) the wear on the rail surface is large near the wave crest and small near the wave trough, work hardening will change the wear difference between the wave crest and wave trough while reducing the wear, resulting in the “peak shaving and valley filling” phenomenon developing faster in the early wave wear period and slower in the later period.

Constitutive Behavior of Titanium Alloy With Dual-Phase Microstructures: Experiments and Modeling

AbstractThe complex composition, size, and distribution of microstructures of titanium (Ti) alloy affect the mechanical properties of titanium alloy and its application in aerospace, ocean technology, and bioengineering. In this paper, the microstructural components and mechanical behavior of Ti80 are first investigated experimentally. According to the experimental observations of the dual-phased microstructures, a mechanism and microstructure-based constitutive model of Ti80 is established to study the quantitative relationship between mechanical behavior and equiaxed αp + lamellar αs + β microstructures of titanium alloys. And the influence of dislocation evolution and accumulation on the strengthening and work-hardening of materials is also explored in detail, especially the contribution of dislocation pile-up zone at the phase boundary between α phase and β phase on the strengthening of materials. Numerical results show that the proposed model can describe the constitutive behavior of Ti80 very well, including yield stress and strain hardening. And various strengthening mechanisms originated from the grain boundaries, phase boundaries of β transformation structure and β precipitation are analyzed. The proposed model is further applied to predict the constitutive behaviors of the titanium alloy with different sizes and various volume fractions of microstructure.

Cryogenic processing of AISI P20 tool steel: Evaluation of mechanical properties and microstructure

The service breakdown of machine components is always a challenging task for the technical engineers, which slows down the production process. Thus there is a rise in maintenance and repair costs. Among several production practices, the cryogenic treatment is one of the outstanding technique which is employed to boost the lifetime of machine components by enhancing the mechanical properties and thereby reducing the probabilities of failures. In present-day and modern technology there is significant use of cryogenic treatment for improving the performance of tool steels. It is a supplementary treatment in which the parts are treated below the sub-zero temperature for various cryo-soaking hours. In this work, an attempt is made to evaluate the consequences of cryogenic treatment on mechanical properties and microstructure of AISI P20 tool steel. The Brinell hardness and Charpy impact strength of work materials are found by varying the cryo-soaking time. A metallurgical microscope is used for assessing the microstructures of the work material under various conditions of cryogenic treatment. The brinell hardness and charpy impact strength of the specimens without austenization and with cryo-treatment were found as 285 HBW, 313 HBW and 8 Joule/mm2, 14 Joule/mm2 respectively for 15 h, 25 h and tempering for 1 h respectively.. Also, with austenization and with cryo-treatment the brinell hardness and impact strength 538 HBW, 506 HBW and 10 Joule/mm2, 8 Joule/mm2 for 15 h, 25 h and tempering for 1 h respectively.

Mathematical Modeling of Material Removal and Surface Roughness in Ultrasonic-Assisted Magnetic Abrasive Flow Machining Process

Abstract Ultrasonic-assisted magnetic abrasive flow machining (UAMAFM) process shows enhanced finishing performance compared to conventional abrasive flow machining (AFM). In this present research paper, mathematical models for M˙R and Ra have been developed for the UAMAFM process by considering both steady-state and transient phenomena. The external ultrasonic and magnetic field assistance enhanced the velocity and length of contact of active abrasives, calculated from the kinematic analysis. The resultant finishing forces have also been evaluated by considering these external aids. The steady-state material removal per finishing cycle remains constant and depends on the velocity of motion, length of contact, resulting forces, number of active abrasives, and work material hardness. The transient material removal per finishing cycle was calculated in terms of the volume of irregularities present over the work surface, i.e., initial surface roughness. The mathematical model for surface roughness was developed in terms amount of material removed (MR), and initial (Ra0) and critical surface roughness (Racr). The predicted values of material removed and surface roughness from developed mathematical models agreed with experimental results with a deviation of 7.80% and 2.44%, respectively.

Influence of grinding parameters on surface roughness and temperature under carbon nanotube assisted MQL

ABSTRACT Conventional flood cooling system has some environmental and economic issues. Minimum quantity lubrication (MQL) has been established as a better strategy to control the machining temperature than conventional flood cooling system. Integrated use of carbon nanotube (CNT) with MQL has been drawing attention in recent times. The purpose was to study the effects of hard grinding with key focus on temperature, surface roughness and chips morphology under the application of CNT-mixed MQL and compressed air. The hardness of work material (AISI 1060 steel) was varied at three values (40, 45 and 50 HRC) with the variation of fluid flow rates and infeed rates to observe the machining behaviour. Experimental plan was established using full factorial design of experiment while mathematical models and optimisation were constructed following response surface methodology (RSM). Optimum output responses were flow rate 75 ml/h, infeed (depth of cut) 10 µm and hardness of material is from 40 to 45 HRC. Fluid flow rate of 75 ml/h resulted in best surface finish while work material of 40 HRC hardness generated lowest temperature while machining. A lower hardness values and a moderate flow rate produced favourable machining outcomes, i.e. lower temperature and improved surface finish.

Low-Cost Tool Design for Pulse-Reverse Electrochemical Machining of Aerospace Alloys via Multiphysics Simulation

Electrochemical machining (ECM) is a manufacturing technology that precisely removes material from metallic workpieces via electrochemical means, typically oxidation, with subsequent dissolution/dispersal of the machining products into a working electrolyte. ECM is able to produce parts with complicated/intricate geometries, and is especially well suited for workpieces to be fabricated from “difficult to cut” materials, as no mechanical interaction occurs between tool and workpiece. In ECM, an electrochemical cell is established with the workpiece as the anode and a shaped tool as the cathode; a suitable electrical potential is then applied while the shaped tool is advanced into the workpiece, resulting in formation of a near-mirror image of the tool in the workpiece. Compared to mechanical or thermal machining processes, where material is subtracted by cutting or by electric/laser discharges, respectively, ECM does not suffer from tool wear or introduce a heat-affected zone to the workpiece. As a result, ECM has strong utility as a manufacturing technology for a wide variety of workpiece materials and ultimate part geometries, and encompasses machining, deburring, boring, radiusing and polishing processes, among others. As noted, ECM provides particular value when applied to high-strength/tough, brittle, galling-prone and/or work-hardening materials such as high strength steels, nickel alloys (e.g., IN718), titanium alloys (e.g., Ti-6Al-4V), cobalt-chrome alloy (Stellite 25), tantalum-tungsten alloy (Ta10W), molybdenum and tungsten.One challenge in practical execution of ECM is the tooling design process, which can require many costly and slow prototyping iterations and which often represents a significant barrier to entry for smaller manufacturing operations that might otherwise benefit from implementation of ECM. Multiphysics simulation has the potential to replace a significant fraction of the initial experimental prototyping effort with rapid, low-cost in-silico methods. This talk will present recent work by Faraday demonstrating a pulse-reverse ECM approach for fabrication of shaped Ni-alloy (IN625/IN718) and Ti-alloy (Ti64/Ti6242) workpieces, along with comparison of the experimentally-obtained results to simulated machined forms produced using the COMSOL Multiphysics® software package. For these preliminary simulation efforts, a 3D primary current distribution model was used to solve for the time-dependent electric field between a moving cathode tool and a workpiece surface, simulating deformation owing to metal dissolution. The simulated and experimental workpiece surfaces showed a satisfactory match for the complex, non-axisymmetric feature geometry embodying a notional form relevant to aerospace turbine and compressor blade manufacture, especially given the preliminary nature of the simulations implemented to date. A cost and lead-time analysis comparing a design process involving all-experimental tool prototyping iterations with one in which initial prototyping is performed computationally reveals the potential for significant cost/time reductions in the latter scenario. Thus, introduction of multiphysics modeling prototyping iterations to the tool design process has the potential to significantly reduce the barrier to entry for newcomers to ECM fabrication. Figure Caption Left to right: Non-axisymmetric tool fabricated by additive-manufacturing methods. Photograph and optical profilometry scan of indentation obtained by pulse-reverse waveform ECM. Indentation form predicted by multiphysics simulation. Figure 1

The role of microstructural characteristics of additively manufactured Alloy 718 on tool wear in machining

This study aims to provide a fundamental understanding of the role of microstructural characteristics influencing tool wear when machining Alloy 718 fabricated using Powder Bed Fusion (PBF). The effects of preferred crystallographic orientation (texture), shape and distribution of grains, local misorientation, type and amount of precipitates as well as the type, size and amount of abrasive carbides, nitrides and oxides on tool wear are investigated in as-built condition and after the standard solutionising and double-aging treatment. The microstructures of workpiece materials and the surfaces of worn tools were examined using different material characterisation techniques, including Scanning Electron Microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD). A dislocation-based approach was used to reveal the cumulative effects of the microstructural characteristics on deformation behaviour and the thermo-mechanical loads on the tools during cutting. The analyses suggest that texture and the extent of material work-hardening prior to the onset of crack formation markedly influence the amount of plastic work and thus heat generation when machining Electron Beam Powder Bed Fusion (EB-PBF) material. The higher heat generation in the cutting zones provokes thermally-induced wear mechanisms like diffusion-dissolution and oxidation. In addition, the larger amount of hard oxide inclusions present in EB-PBF material leads to higher wear by abrasion. In contrast to the prevailing experimental approaches in this field, the present investigation is built on a physics-based framework to understand the fundamental aspects that govern material deformation and heat generation in cutting and, consequently, tool wear mechanisms. This framework can be used for machinability assessment of any alloy manufactured by different additive manufacturing (AM) technologies and for optimising the process-chain, including printing strategies and thermal post-treatments, to improve the machinability of AM alloys by tailoring their microstructure.

Material Modeling of PMMA Film for Hot Embossing Process.

This study provides an analysis of the hot embossing process with poly methyl methacrylate (PMMA) film. The hot embossing process engraves a fine pattern on a flexible film using a stamp, applied heat and pressure. As the quality of the embossing pattern varies according to various process variables, the mechanism of making the embossed shape is complicated and difficult to analyze. Therefore, analysis takes much time and cost because it usually has to perform a lot of experiments to find an appropriate process condition. In this paper, the hot embossing process was analyzed using a computational analysis method to quickly find the optimal process. To do this, we analyzed the embossing phenomenon using the finite element method (FEM) and arbitrary Lagrangian–Eulerian (ALE) re-mesh technique. For this purpose, we developed a constitutive model considering the strain, strain rate, temperature-dependent stress and softening of the flexible film. Work hardening, strain softening, and temperature-softening behavior of PMMA materials were well described by the proposed method. The developed constitutive model were applied in the embossing analysis via user-subroutine. This proposed method allowed a precise analysis of the phenomenon of film change during the hot embossing process.

Non-Linear through-Hole Fabrication By Electrochemical Machining

Electrochemical machining (ECM) is a manufacturing technology that precisely removes material from metallic workpieces by electrochemical oxidation and dissolution into a working electrolyte. ECM is especially well suited for workpieces to be fabricated from "difficult to cut" materials, and is able to produce parts with complicated/intricate geometries. In ECM, an electrochemical cell is established with the workpiece as the anode and a shaped tool as the cathode; after engaging a suitable electrical potential, the shaped tool is advanced into the workpiece and a mirror image of the tool is formed. Compared to mechanical or thermal machining processes, where material is subtracted by cutting or by electric/laser discharges, respectively, ECM does not suffer from tool wear or introduce a heat-affected surface layer to the workpiece. As a result, ECM has strong utility as a manufacturing technology for a wide variety of workpiece materials and ultimate part geometries, and encompasses machining, deburring, boring, radiusing and polishing processes, among others. As noted, ECM provides particular value when applied to high-strength/tough, brittle, and/or work-hardening materials such as high strength steel, chrome-copper alloy (C18200), nickel alloy (IN718), cobalt-chrome alloy (Stellite 25), tantalum-tungsten alloy (Ta10W), molybdenum and tungsten, since the material removal process involves no mechanical interaction between the tool and the part.This talk will summarize recent work performed to demonstrate the feasibility of non-linear through-hole machining in tubular metallic substrates by ECM, through application of a multi-step forming process. One category of feature that is often challenging to fabricate in hard-to-machine materials is a non-linear passage or through-hole. This is in contrast to a straight passage, which is generally uncomplicated to achieve with many methods, whereas in general non-linear through-holes in tube walls must be machined from both the inner and outer diameter of the wall. For easily-machined materials, machining steps taking place on the inner diameter of the workpiece can be accomplished with a sufficiently advanced multi-axis CNC mill, but for hard-to-machine materials it is difficult or impossible to achieve the necessary bearing force and/or angle of approach of the tool. Thermal machining methods (electric discharge machining, etc.) are viable in some cases, but as noted above will result in a heat-affected layer on the machined surface that is problematic in many applications. Experimental ECM results will be presented for fabrication of "chevron" through-hole features (~90° path axis deflection) in both planar and annular workpieces, embodying a proof-of-concept demonstration and an early step in development of an ECM methodology for fabricating integrated muzzle brake vane apertures directly into the barrel wall of large-bore cannon. Figure Caption (Top left) Patent drawing of modular muzzle brake concept for cannon, showing overall design and cross-section of a single vane, with vane passage geometry highlighted in orange. (Bottom left) Schematic 3D model of a cannon barrel with integrated muzzle brake vanes. (Top right) Schematic of two-sided ECM fabrication of nonlinear “chevron” passage in a composite stack of flat coupons. (Bottom right) Photographs of cross-sectioned flat steel coupons with fabricated “chevon” passages. Reference (from figure) Cler, D.L. and D. Forliti. U.S. Patent No. 7,600,461, issued 13 Oct 2009. Figure 1

Experimental investigation of milling process under optimum lubricant use

Performance of the machining and the efficiency of milling operation depend on several process variables among which hardness of work material is of great significant. In this study, experimentation was carried out to investigate the effect of work hardness on end milling process. Workpiece material hardness is used as a noise factor. Input parameters used are spindle speed, feed; depth of cut and tool diameter.The experiments performed under wet and minimum Quantity lubrication and results of both compared. further for getting optimal lubricant conditions the experiments performed for various levels of flow rates of minimum quantity lubrication to get the best optimal setting. Output parameters are surface roughness, material removal rate, cutting force and tool wear. Design of Experiment (DOE) with Taguchi L27 Orthogonal Array (OA) has been explored to produce 27 specimens on Al2024 aluminium by end milling operation at three different levels of hardness of material. The experiments performed under wet and minimum quantity lubrication condition and results compared. Further For optimal lubricant condition the experiments performed at various flow rate of Minimum Quantity Lubrication and “best” optimal setting is identified.

Validating Continuum Model for Onset of Adiabatic Shear Banding during High Speed Cutting by Finite Element Method

High-speed cutting (HSC) is frequently adopted to manufacture parts in many industries, including aerospace and automotive. To manufacture high-quality parts, adiabatic shear banding (ASB), often observed on serrated chips of various metallic materials during the HSC process, should be suppressed and studied. ASB is formed due to work hardening of metallic materials and work softening induced by adiabatic heating. The onset of ASB during the orthogonal cutting of Ti6Al4V is modeled based on the continuum mechanics, taking both work hardening and work softening into considerations. The model is validated by finite element method (FEM) and experiments. Moreover, the ASB onset process is simulated in FEM to reveal the ASB formation mechanism. The effect of the mechanical properties of Ti6Al4V on the onset of ASB is investigated based on the Johnson-Cook model. The investigation reveals the main factors that affect the onset of ASB during the HSC process. Future work includes characterizing the mechanical behavior of Ti6Al4V after the onset of ASB during a cutting process by coupling the continuum mechanics and micromechanics.

Influence of grain size distribution on mechanical properties and HDI strengthening and work-hardening of gradient-structured materials

Gradient structures (GS) with various grain size distributions are successfully architectured in a commercial low-alloying steel by using the pre-torsion and thermal annealing routes, and the corresponding mechanical properties and hetero-deformation induced (HDI) strengthening and work-hardening are investigated. Results demonstrate that an optimal grain size distribution from ~5.0 ± 2.8 μm at the surface to 11.1 ± 4.5 μm at the center leads to the maximum HDI strengthening of ~325 MPa. The HDI work-hardening intensifies continuously with the decreased average grain size of the GS due to the formation of abundant geometrical necessary dislocations (GNDs) whose density decreases abnormally from the fine-grain surface to the coarse-grain core caused mainly by the interactions between the short-range GNDs and long-range GNDs. Thanks to the HDI strengthening and work-hardening, the yield strength increases with a reduction of uniform ductility approximately following the linear inverse rule, in stark contrast to the banana-shaped strength-ductility trade-off of monolithic materials, and an exceptional strength-ductility synergy is achieved.

WITHDRAWN: Experimental investigation and optimization of surface grinding on EN31AM steel using Taguchi and ANN

Grinding is the machining processes; it is used to enhance the dimensional accuracy and surface quality of workpiece. The surface grinding process is affected by the different process parameters such as grinding wheel speed, material removal rate (MRR), number of passes, grinding wheel grain size, work piece speed, material hardness and depth of cut respectively. The feed and speed are the important factors because by increasing these factors will directly impacts on surface roughness (SR). Even though, the SR is reduced by improving the MRR. Surface grinding is the major process in metals cutting applications; it is widely used in finishing operations of cutting machining processes. SR and MRR are the significant output responses in the manufacturing relating to quality and quantity. In this article, an experimental investigation of surface grinding of EN31AM steel is studied to minimize the SR and maximize MRR for the optimization of grinding process parameters. In addition, artificial neural network (ANN) and Taguchi also employed for optimizing the input process parameters such as depth of cut, feed, and speed.

Microstructure Analysis of IS2062 Plates Cladded with SS2594 by TIG Welding Process

The power requirement of industries has been growing like anything now-a-days. The components involved in the production of power have also attracted more attention in industrial revolution. The present work focuses on improving the hardness and shear resistance of IS2062 work material used in the manufacturing of fire tubes in thermal power plants. The cladding of surface was carried out by Tungsten Inert Gas (TIG) welding with the use of SS2594 duplex steel as surface coating material. Hardness test results revealed that cladding process have raised the value from 170 to 411. Microstructural analysis has revealed the formation of refined grains at the clad zone due to continuous recrystallization of martensite. It has happened because of higher gas flow rate during welding. Macroscopic analysis has proved the increase in current during the process improved the diffusion of SS2594 material into the base metal IS2062.

Development of Al-SiCp nano composite material and study of its machining process using coated carbide inserts

Abstract The current research paper deals with the development of aluminium (Al) and Silicon Carbide (SiCp) nano composite material with the assistant of ultrasonicator. In this fabrication process, Aluminium is considered as matrix and Silicon Carbide nano particle is used as reinforcement. The fabrication work produces three samples by using 1, 1.5 and 2 weight percentages of SiCp nano particle mixing with aluminium metal matrix. From the experimental study and review of literature, it was noted that 2 wt% of SiCp when mixed with aluminium (Al) metal matrix, gives the best sample and suitable for machining operation. The machining of the work sample was conducted in a CNC lathe by coated carbide cutting tool. In this process, Design of Experiment i.e. Taguchi L16 orthogonal array was used for three parameters i.e. feed, depth of cut as well as speed at four different levels. The flank wear of tool and surface roughness of work material was optimized by using Principal Component Analysis (PCA). The Scanning Electron Microscopic (SEM) technique was conducted to find out the wearing status of the cutting tool. The chip morphology study was conducted to find out the ductility and hardness of the work material. The other important technique i.e. Analysis of Variance (ANOVA) is used to achieve the most influence parameters for the machining process.