Effect of Nose Radius on surface roughness and Cutting Force in orthogonal cutting

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ISSN 2395-1621 Effect of Nose Radius on surface roughness and Cutting Force in orthogonal cutting #1 Dongare Y.S., #2 Belkar S.B. 1 ydongare245@gmail.

1 ISSN Effect of Nose Radius on surface roughness and Cutting Force in orthogonal cutting #1 Dongare Y.S., #2 Belkar S.B. 1 ydongare245@gmail.com #12 Mechanical Department, Savitribai Phule University,Pune. ABSTRACT Machining is a common manufacturing technique for production process. In manufacturing process different types of cutting tool are used for cutting the different metals. The cutting tool having different types such as single point cutting tool, drill and many more. The single point cutting tool having different parameters such as rake angle, flank angle, nose radius and other tool geometry. In the cutting parameter rake angle, clearance angle and nose radius having main effect on metal cutting. During operation of the tool different parameters affect on the performance of the tool and cutting parameter. In experimentation we were take five different nose radiuses such as 0.5,1.0,1.5,2.0,2.5(mm) for turning the EN8M material and also take three different feed rate 0.05,0.1,0.2(mm/min).The cutting force during turning is measure by using two dimensional tool dynamometer and surface roughness is measure by using profilometer.. From this conclude that cutting force increases with increase in nose radius. Surface Finish increase with increase in nose radius. ARTICLE INFO Article History Received :18 th November 2015 Received in revised form : 19 th November 2015 Accepted : 21 st November, 2015 Published online : 22 nd November 2015 Keywords nose radius, tool dynamometer, surface roughness I. INTRODUCTION Stringent control on the quality of machined surface and sub-surface during turning is most important consideration a part from considering the tool life. In order to attain sufficiently high production rates at minimum cost, optimization of cutting tool geometry is necessary. The design of cutting edge geometry and its influence on machining performance have been a research topic in metal cutting for a long time. The nose radius having more effect on the cutting force and surface roughness. Feed rate also having the significant effect on the cutting force and surface roughness. As nose radius increases cutting force and feed force increases and nose radius increases surface roughness get decreases. In this project the various forces such as cutting force, feed force and the axial force have been found out with the variation in depth of cut for different materials like aluminium, brass, mild steel & nylon. Graphs are drawn on how theseforces vary with the variation in the depth of cut.[1-5] II. LITERATURE REVIEW T.H.C. Childs et.al. [1] Observed Surface finishes from turning and facing with round nosed tools. It is wellknown, in turning or facing at a feed f with a tool of nose radius r n, that the peak-to-valley roughness that is created, Rz for example, usually equals or exceeds the kinematic value f 2 /(8r n ) and that, below some limiting value of f, Rz becomes independent of f and may even increase as f reduces further. A.H. Adibi-Sedeh, et. al.[3] worked on Upper bound analysis of oblique cutting with nose radius tools. Though much machining research is focused on situations in which cutting happens along one straight cutting edge (called primary cutting edge or major cutting edge or side cutting edge), in reality, most of the machining operations include cutting along a nose radius joining the primary cutting edge to a secondary cutting edge. M. Xiao et.al.[5] studied on the effect of tool nose radius in ultrasonic vibration cutting of hard metal. Hardened steel, Ni-based alloys and brittle materials are very difficult to machine using conventional cutting methods. Y. Kevin Chou and Hui 2015, IERJ All Rights Reserved Page 1

Song [7] worked on Tool nose radius effects on finish hard turning. Tool nose radius effects on finish turning of hardened AISI 52100 steels have been investigated.

Results show that large tool nose radii only give finer surface finish, but comparable tool wear compared to small nose radius tools. Specific cutting energy slightly increases with tool nose radius.

2 Song [7] worked on Tool nose radius effects on finish hard turning. Tool nose radius effects on finish turning of hardened AISI steels have been investigated. Surface finish, tool wear, cutting forces, and, particularly, white layer (phase transformation structures) were evaluated at different machining conditions. Results show that large tool nose radii only give finer surface finish, but comparable tool wear compared to small nose radius tools. Specific cutting energy slightly increases with tool nose radius. Experiments were carried out on a Kirloskar Turn Master 40 lathe setup using High speed steel (HSS) cutting tools for the machining of EN8M cylindrical workpiece, which is having size Ø25mm 100mm as shown in fig.i..a total of 15 experiments were performed with 5 different nose radiuses 0.5, 1, 1.5, 2, 2.5(mm) at a constant cutting speed of 180m/min and depth of cut of 1 mm at 3 different feed rates 0.2,0.4,0.5mm/rev as shown in Table III.The cutting force were measured by tool dynamometer as shown in fig II. III WORK MATERIAL, CUTTING TOOL AND METHOD EN8M steel has been used as the work piece material to conduct all the experiments. These types of materials are widely used in the industrial applications. For conducting experiments cylindrical bar diameter of 25 mm and length is 100 mm used. Prior to the experiments the specimens turned with 1 mm cutting depth in order to remove the outer layer, which could appear discontinuous or unexpected hardening distribution due to their extrusion production process. The chemical composition and mechanical properties of the selected work piece material are listed in Table I and Table II TABLE I CHEMICAL COMPOSITION OF EN8M STEEL Chemical composition Wt % Carbon C 0.38 Manganese Mn 1.26 Silicon Si Phosphorous P Sulphur S 0.19 TABLE III MECHANICAL PROPERTIES OF EN8M STEEL Hardness HBR Ultimate Tensile strength(n/mm 2 ) Yield Tensile strength(n/mm 2 ) Elongation (%) Single point HSS (High speed steel) cutting tools were used in all the experiments. New tools were used for all experiments to ensure that the cutting force and surface roughness should get proper values. Different nose radiuses were produced in each tool with the help of a tool cutter and grinder machine. The various tool nose radiuses are: 0.5, 1, 1.5, 2, and 2.5(mm) and a constant rake angle and clearance angle: 12 and 8 respectively were used. IV MACHINING TOOL AND CUTTING CONDITIONS Fig.1 Kirloskar Turn Master - 40 lathe machine. Fig.2 Lathe Tool Dynamometer (Sensing and Display Unit) TABLE IIIII MACHINING PARAMETERS AND EXPERIMENTS RESULTS Experiment Feed Nose Trust Feed Ra(µm) No. Rate (mm/rev) radius(mm) Force (Ft)N Force(Ff)N , IERJ All Rights Reserved Page 2

3 The nose radius having the significant effect on the surface roughness. As nose radius increases the surface roughness goes on decreases. The effect of nose radius on surface roughness as shown below. V RESULTS AND DISCUSSION 1) Effect of nose radius on cutting force A set of experiments were carried out as per Table III in order to measure the effect of change in nose radius and feed rate on cutting force in two directions(such as trust force and feed force)). The experimental results were shown in Table III. The cutting forces were measured by using tool dynamometer as shown in fig.2. As nose radius increases the cutting force and feed force increases as shown following graph. Fig.6 at constant f=0.5mm/rev ig.3 at constant f=0.5mm/rev F Fig.7 at constant f=0.4mm/rev Fig.4 at constant f=0.4mm/rev Fig.8 at constant f=0.2mm/rev 3) E ffect of feed rate on surface roughness Effect of feed rate on the surface roughness as shown below figure. As feed rate increases the surface roughness also increases. Fig.5 at constant f=0.2mm/rev 2) Effect of nose radius on the surface roughness 2015, IERJ All Rights Reserved Page 3

4 Fig.9 at constant r=2.5mm Fig.13 at constant r=0.5mm VI CONCLUSION Fig.10 at constant r=2mm In this paper a total of 15 experiments were carried on to find the effect of nose radius and feed rate on the cutting forces and surface roughness during orthogonal turning of EN8M steel using HSS cutting tool. From the results of this work the following Conclusions can be drawn t was observed that as nose radius increases the cutting force also get increases with nose radius. urface roughness gets decreases with increases in nose radius. As feed rate increases the Surface roughness gets increases. Fig.11 at constant r=1.5mm ACKNOWLEDGMENT Thanks to Mr. Belkar S.B. for his valuable contribution in doing this project. Fig.12 at constant r=1mm REFERENCES [1] T.H.C. Childs, K. Sekiya, R. Tezuka, Y. Yamane, D. Dornfeld,D.-E. Lee, S. Min, P.K. Wright, Surface finishes from turning and facing with round nosed tools,cirp Annals - Manufacturing Technology 57 (2008) [2] SebastienCampocasso, Gerard Poulachon, Jean- Philippe Costes, Stephanie Bissey- Breton, An innovative experimental study of corner radius effect on cutting forces, CIRP Annals - Manufacturing Technology 63 (2014) [3] A.H. Adibi-Sedeh, V. Madhavan, B. Bahr, Upper bound analysis of oblique cutting with nose radius tools, International Journal of Machine Tools & Manufacture 42 (2002) [4] T.Y. Lim, M.M. Ratnam, Edge detection and measurement of nose radii of cutting tool inserts from scanned 2-D images, Optics and Lasers in Engineering 50 (2012) , IERJ All Rights Reserved Page 4

5 [5] M. Xiao, K. Sato, S. Karube, T. Soutome, The effect of tool nose radius in ultrasonic vibration cutting of hard metal, International Journal of Machine Tools & Manufacture 43 (2003) [6] Chung-Shin Chang, Gwo-Chung Tsai, A force model of turning stainless steel with worn tools having nose radius, Journal of Materials Processing Technology 142 (2003) [7] Y. Kevin Chou, HuiSong, Tool nose radius effects on finish hard turning, Journal of Materials Processing Technology 148 (2004) [8] D.I. Lalwani, N.K. Mehta, P.K. Jain, Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel, journal of materials processing technology 206 (2008) [9] ] T.H.C. Childs, D. Dornfeld, D.-E. Lee, S. Min, K. Sekiya, R. Tezuka, Y. Yamane, The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools, CIRP Journal of Manufacturing Science and Technology 1 (2008) [10] S. Thamizhmanii*, B. Bin Omar, S. Saparudin, S. Hasan, Surface roughness analyses on hard martensitic stainless steel by turning,journal of Achievements in Materials and Manufacturing Engineering,Volume 26 Issue 2 February [11] R. Vinayagamoorthy and M. Anthony Xavior, Significant the Effect of Cutting Parameters on Surface Roughness in Precision Turning in TI-6AL- 4V, Middle-East Journal of Scientific Research 17 (11): , [12] Rishu Gupta, AshutoshDiwedi, Optimization of Surface Finish and Material Removal Rate with Different Insert Nose Radius for Turning Operation on CNC Turning Center,International Journal of Innovative Research in Science, Engineering and Technology,Vol. 3, Issue 6, June [13] HasanGökkaya, The Effects of Machining Parameters on Cutting Forces,Surface Roughness, Built-Up Edge (BUE) and Built-Up Layer(BUL) During Machining AA2014 (T4) Alloy,Strojniškivestnik - Journal of Mechanical Engineering 56(2010)9, [14] Zhanqiang Liu, Peng Zhang, PengGuo and Xing Ai, Surface Roughness in High Feed Turning with Wiper Insert, Key Engineering Materials Vols (2008) pp [15] Pragnesh. R. Patel, Prof. V. A. Patel, Effect of machining parameters on Surface roughness and Power consumption for 6063 Al alloy TiC Composites (MMCs), International Journal of Engineering Research and Applications,Vol. 2, Issue 4, July- August 2012, pp , IERJ All Rights Reserved Page 5

Effect of Rake Angles on Cutting Forces for A Single Point Cutting Tool

Effect of Rake Angles on Cutting Forces for A Single Point Cutting Tool Pradeesh A. R. 1 ; Mubeer M. P 2 ; Nandakishore B 3 ; Muhammed Ansar K 4 ; Mohammed Manzoor T. K 5 ; Muhammed Raees M. U 6 1Asst.