TOOL LIFE PERFORMANCES AND SURFACE … · 2018-01-19 · Annealing Process on Machinabilty and Tool Life of Drill Bit for 20MNCR5 Steel. International Journal of Mechanical Engineering

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 8, August 2017, pp. 140–147, Article ID: IJMET_08_08_016

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

TOOL LIFE PERFORMANCES AND SURFACE

ROUGHNESS CHARACTERISTICS WHEN

TURNING AUSTENISED AND QUENCHED

BEARING STEEL WITH CERAMICS AND HSS

K. Vijay Krishna Varma

Department of Mechanical Engineering, GITAM University Hyderabad, Telangana.

V.S.V Sai Sumanth

Department of Mechanical Engineering, GITAM University Hyderabad, Telangana.

ABSTRACT

It is necessary to select the most appropriate cutting parameters and cutting tools

in order to improve cutting efficiency, process at low-cost, and produce high-quality

products. Of the present available cutting tools materials, ceramic or cubic boron

nitride (CBN) cutting tools are the best candidates and are widely used in turning the

hardened steels owing to their high hardness and high melting point 1,2. The turning

of hardened steels by selecting the right cutting tools and cutting parameters produces

surface finishes with grinding quality. The main aim of the project is to determine tool

life performances of cutting tools made of ceramic and High Speed Steel and surface

roughness of AISI 52100 steels are investigated experimentally under different cutting

conditions in turning. The parameters cutting speed, feed rate and depth of cut are

varied.

Keywords: AISI 52100 steel, Feed, Cutting Speed, Depth of cut, Cutting force

calculation.

Cite this Article: K. Vijay Krishna Varma and V.S.V Sai Sumanth, Tool Life

Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics and Hss, International Journal of Mechanical

Engineering and Technology 8(8), 2017, pp. 140–147.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

1. INTRODUCTION

Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,

describes a helical tool path by moving more or less linearly while the work piece rotates.

Usually the term "turning" is reserved for the generation of external surfaces by this cutting

action, whereas this same essential cutting action when applied to internal surfaces (that is,

holes, of one kind or another) is called "boring". Thus the phrase "turning and boring"

K. Vijay Krishna Varma and V.S.V Sai Sumanth


categorizes the larger family of (essentially similar) processes. The cutting of faces on the

work piece (that is, surfaces perpendicular to its rotating axis), whether with a turning or

boring tool, is called "facing", and may be lumped into either category as a subset.

2. EXPERIMENTAL INVESTIGATION

Turning operations are conducted on AISI 52100 steel taking cutting tools made of ceramic

and High Speed Steel to determine the tool life and surface roughness of AISI 52100 steel

under different cutting conditions in turning. The parameters cutting speed, feed rate and

depth of cut are varied.

WORK PIECE MATERIAL AISI bearing steel with 32mm dia and 122mm length

FEED 260mm/min, 350mm/min, 500mm/min

CUTTING SPEED 850rpm, 1300rpm, 1500rpm

DEPTH OF CUT 0.2mm, 0.3mm, 0.4mm

EXPERIMENTAL PHOTOS

Figure 1 Turning Machine Figure 2 Facing the work piece

Table 1 Machining Parameters and their respective values

JOB NO. CUTTING SPEED

(rpm) FEED RATE (mm/min) DEPTH OF CUT (mm)

1 850 260 0.2

2 1300 350 0.3

3 1500 500 0.4

EXPERIMENT No -1

The experiments are done on the CNC turning machine with the following parameters:

Cutting tool material HSS

Work piece material AISI bearing steel

Feed 260mm/min, 350mm/min, 500mm/min

Cutting speed 850rpm, 1300rpm, 1500rpm

Depth of cut 0.2mm, 0.3mm, 0.4mm

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics and Hss


Table no 2– Observed Surface finish values using HSS as cutting tool

JOB NO. CUTTING

SPEED (rpm)

FEED RATE

(mm/min)

DEPTH OF CUT

(mm)

SURFACE

FINISH (Ra)

1 850 500 0.2 1.81

2 1300 350 0.3 1.79

3 1500 260 0.4 1.54

EXPERIMENT No -2

Cutting tool material Ceramic

Work piece material AISI bearing steel

Feed 260mm/min, 350mm/min, 500mm/min

Cutting speed 850rpm, 1300rpm, 1500rpm

Depth of cut 0.2mm, 0.3mm, 0.4mm

Table 3 Observed Surface finish values using Ceramic as cutting tool

JOB NO. CUTTING SPEED

(rpm)

FEED RATE

(mm/min)

DEPTH OF CUT

(mm)

Surface finish

(Ra)

1 850 500 0.2 1.56

2 1300 350 0.3 1.27

3 1500 260 0.4 0.92

3. 3D MODEL

Figure 3 Final Model Figure no 4: 2D Drafting

Table 4 Cutting Forces

JOB NO. SPINDLE SPEED

(rpm)

FEED RATE

(mm/min)

DEPTH OF CUT

(mm)

FORCE

(N)

1 850 500 0.2 130

2 1300 350 0.3 195

3 1500 260 0.4 260



4.STRUCTURAL ANALYSIS OF TURNING AISI 52100 STEEL WITH

CERAMIC AND HSSTOOL

Table 5 Boundary Conditions:

Sl.No Material Young’s Modulus

(MPa) Density (Kg/mm3) Poisson’s Ratio

01 AISI 52100 210000 0.00000781 0.3

02 CERAMIC 380000 0.00000396 0.35

03 HSS 335000 0.00000435 0.3

CUTTING TOOL MATERIAL – CERAMIC (FORCE = 130N)

Figure 5 Total Deformation

Figure 6 Equivalent Stress

Figure 7 Equivalent Elastic Strain




FORCE - 195N

Figure 8: Total Deformation



FORCE – 260N






CUTTING TOOL MATERIAL –HSS(FORCE =130 N)

Figure no 14: Total Deformation



FORCE -195 N







FORCE – 260 N






5. RESULT TABLE

Table 6 Cutting tool – Ceramic

Force(N) Deformation(mm) Stress(N/mm2) Strain

130 0.0020438 339.33 0.0009092

195 0.0032701 542.89 0.0014546

260 0.0036789 610.73 0.0016364

Table 7 Cutting tool - HSS

Force(N) Deformation(mm) Stress(N/mm2) Strain

130 0.0020448 310.64 0.00094166

195 0.0032716 496.99 0.0015066

260 0.0036806 559.1 0.0016948

6. CONCLUSION

The surface finish of the work piece turned using different cutter materials of Ceramic and

HSS materials are investigated by experimentation. By observing the surface roughness

results, the increasing the spindle speeds and decreasing the feed rates the surface finish

increases.

By observing the theoretical calculations and by surface roughness results, the tool life is

reduced for Ceramic tool than HSS tool. By observing the analysis results, the deformation

and stress values are less when HSS tool is used than Ceramic tool.

REFERENCES

[1] Using the Response Surface Method to Optimize the Turning Process of AISI 12L14 Steel

[2] Optimization of Process Parameters of Turning Parts: A Taguchi Approach by Neeraj

Sharma, Renu Sharma

[3] The Effect of Tool Construction and Cutting Parameters on Surface Roughness and

Vibration in Turning of AISI 1045 Steel Using Taguchi Method by Rogov Vladimir

Aleksandrovich, GhorbaniSiamak

[4] Parametric investigation of turning process on mild steel aisi 1018 material by J. M.

Gadhiya, P. J. Patel

[5] Evaluation and Optimization of Machining Parameter for turning of EN 8 steel by Vikas

B. Magdum, Vinayak R. Naik

[6] M.V. Babu Tanneru, Dr. J. Krishnaraj and K. Vijaya Krishna Varma, Influence of

Vegetable Oil Based Cutting Fluids On Tool Wear and Surface Roughness In Milling En8

Steel Using HSS and Tungsten Carbide Tool, International Journal of Civil Engineering

and Technology, 8(6), 2017, pp. 882–890

[7] Dr. Lakhwinder Pal Singh and Guravtar Singh Mann Experimental Study of Effects of

Annealing Process on Machinabilty and Tool Life of Drill Bit for 20MNCR5 Steel.

International Journal of Mechanical Engineering and Technology, 8(7), 2017, pp. 1906–

1915.

Documents

TOOL LIFE PERFORMANCES AND SURFACE … · 2018-01-19 · Annealing Process on Machinabilty and Tool Life of Drill Bit for 20MNCR5 Steel. International Journal of Mechanical Engineering