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http://www.iaeme.com/IJMET/index.asp 140 editor@iaeme.com
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
http://www.iaeme.com/IJMET/index.asp 141 editor@iaeme.com
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
http://www.iaeme.com/IJMET/index.asp 142 editor@iaeme.com
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
K. Vijay Krishna Varma and V.S.V Sai Sumanth
http://www.iaeme.com/IJMET/index.asp 143 editor@iaeme.com
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
Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and
Quenched Bearing Steel with Ceramics and Hss
http://www.iaeme.com/IJMET/index.asp 144 editor@iaeme.com
FORCE - 195N
Figure 8: Total Deformation
Figure 9 Equivalent Stress
Figure 10 Equivalent Elastic Strain
FORCE – 260N
Figure 11 Total Deformation
Figure 12 Equivalent Stress
K. Vijay Krishna Varma and V.S.V Sai Sumanth
http://www.iaeme.com/IJMET/index.asp 145 editor@iaeme.com
Figure 13 Equivalent Elastic Strain
CUTTING TOOL MATERIAL –HSS(FORCE =130 N)
Figure no 14: Total Deformation
Figure 15 Equivalent Stress
Figure 16 Equivalent Elastic Strain
FORCE -195 N
Figure 17 Total Deformation
Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and
Quenched Bearing Steel with Ceramics and Hss
http://www.iaeme.com/IJMET/index.asp 146 editor@iaeme.com
Figure 18 Equivalent Stress
Figure 19 Equivalent Elastic Strain
FORCE – 260 N
Figure 20 Total Deformation
Figure 21 Equivalent Stress
Figure 22 Equivalent Elastic Strain
K. Vijay Krishna Varma and V.S.V Sai Sumanth
http://www.iaeme.com/IJMET/index.asp 147 editor@iaeme.com
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.
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