International Journal of Pure and Applied Mathematics Volume 116 No. 15 2017, 25-29 ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version) url: http://www.ijpam.eu Special Issue
ijpam.eu
SINGLE POINT CUTTING TOOL WEAR ANALYSIS IN CNC TURNING CENTER Dr.Venkatesh Babu1, Durairaj VP 2 Professor, Department of Mechanical Engineering, BIST, BIHER, Bharath University, Chennai-73 2 Asst.Professor, Department of Mechanical Engineering, Bharath University, BIHER, Chennai-73. 1
[email protected],
[email protected] 1
Abstract: The tool wear of cutting tools has a very strong impact on the product quality as well as on the efficiency of the machining processes. Despite the current high automation level in the machining industry, a few key issues prevent complete automation of the entire turning process. One of these issues is tool wear, which is usually measured off the machine tool. Therefore, its in-line characterization is crucial. Monitoring tool wear in machining processes is one of the critical factors in reducing downtime and maximizing profitability and productivity. A worn out tool can deteriorate the surface finish or dimensional accuracy of the part. Due to the uncertainties that originate from machining, work piece material composition, and measurement, predicting tool wear is a challenging task in modern manufacturing processes. There are two ways to analyze tool wear, first is for R&D and second is for industries. For R & D purposes, tool life is always assessed or expressed by span of machining time in minutes, whereas, in industries besides machining time in minutes some other means are also used to assess tool life, depending upon the situation, such no. of pieces of work machined, total volume of material removed&total length of cut. Here,we mainly consider no of piece of work machined by pernose of the cutting tool. This study presents tool wear characterization of carbide cutting tool inserts coated with titanium nitride (TiN) in a single point turning operation of 41Cr4 steel. A setof experiments of 4 settings of feed rate with different coolant proportion were performed with proper monitoring of tool changing on a CNC turning center. The result of this work show that better colant proportion and at adequate feed rate improves the quality of the product and reduces the number of rejection of product.
25
1. Introduction Turning is the first most common method for cutting and especially for the finishing machined parts. In a turning operation, it is important task to select cutting parameters for achieving high [5]cutting performance. Usually, the desired cutting and geometric parameters are determined based on experience or by use of a handbook. Cutting parameters are reflected on surface roughness, surface texture and dimensional deviations of the product. Surface roughness, which is used to determine and to evaluate the quality of a product, is one of the major quality attributes of a turning product. [6]To select the cutting parameters properly, several mathematical models based on statistical regression or neural net-work techniques have been constructed to establish the relationship between the cutting performance and cutting parameters.It is well known that as the tool life increase, [4]the tool wear reduce. It is observed that tool life is inversely proportional to tool wear. By using mathematical modeling it is also observed that the tool life is increase and tool wear is decrease. There are many significant to be analyzed in order to optimize the cutting[7] and geometric parameter because it will affect the quality and the productivity of that material. Optimization of cutting and geometric parameters is usually a difficult work, where the following aspects are required like knowledge of machining, empirical equations relating the tool life, specification of machine tool capabilities and knowledge of mathematical and numerical optimizationtechniques also is compulsory. [8]There are two ways to analyze tool wear, [3]first is for R&Dand second is for industries. Above mentioned techniques used in R&D department for setting cutting parameters.In R&D department tool life is always assessed or expressed by span of machining time in minutes, whereas, in industries besides machining time
International Journal of Pure and Applied Mathematics
in minutes some other means are also used to assess tool life, depending upon the situation, ion, such no. of pieces of work machined total volume of material removed total length of cut. [9] In this study we mainly consider number of piece of work machined by pernose of the tool.[11 tool.[11-12] Tool wear Wear is loss of material on an asperity or micro micro-contact, or smaller scale, down to molecular or atomic removal mechanisms. It usually progresses continuously. [13]Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tipped tools, tool bits,, or drill bit that are used with machine tools.Wear is loss of material on an asperity or micro microcontact, or smaller scale, down to molecular or atomic removal mechanisms. It usually progresses continuously. [14] Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tipped tools, tool bits, or drill bits that are used with machine tools.[15] Mainly considered types of tool wear
Special Issue
Crater wear consists of a concave section on the tool face formed by the action of the chip sliding on the surface. Crater wear affects the mechanics of the process increasing the actual rake angle of the cutting tool and consequently, making cutting easier. At the t same time, the crater wear weakens the tool wedge and increases the possibility for tool breakage. In general, crater wear is of a relatively small concern.[24-29] 29] Types of Tool Used 1. TNMG 160408 FV CU25 (for turning) 2. TNMG 160404 CQ CA5525 (for finish boring turning) 3. PENTA 24 N 150 J 010 IC908(for grooving)
● Nose wear ● Flank wear ● Crater wear Nose wear Nose wear occurs on the tool corner. [16]Can be considered as a part of the wear land and respectively flank wear since there is no distinguished boundary between the corner wear and flank wear land. We consider nose wear as a separate wear type because of its importance [17]for the precision of machining. Nose wear actually shortens the cutting tool thus increasing gradually the dimension of machined surface and introducing a significant dimensional error in machining, which can reach values of about 0.03~0.05 mm.[18] Flank wear Flank wear occurs on the tool flank as a result of friction between the machined surface of the work piece and the tool flank. Flank wear appears in the [19]form of so socalled wear land and is measured by the width of this wear land, VB, Flank wear affects to the great extend the mechanics of cutting. Cutting forces increase significantly with flank wear. If the amount of flank wear exceeds some critical value (VB > 0.5~0.6 mm), the excessive cutting force may cause tool failure.[20-23] 23] Crater wear
2. Mehodlogy In this project, we are analaysing the wear of the single point cutting tool by using four trial in terms of no. of products by decreasing feed rate and changing coolant proportion. So we can increase the tool life and also improve quality of the product [30] Suggestion •
Proper tool changing should be monitored
•
Coolant proportion increased from 0.75 to 1.25
•
Decrease feed rate (mm/rev)
1st operation Rough turning 0.15 to 0.12 turning0.15 to 0.12 Finish turning 0.25 to 0.18 turning 0.12 to 0.10
26
Rough Finish
International Journal of Pure and Applied Mathematics
2nd operation Roughboring 0.07
0.15 to 0.15
Finishboring 0.15 to 0.12 chamfer0.15 to 0.12
Grooving Id
3. Conclusion •
Tool changing method chart introduced
•
Even through operation cycle time increased rejection rated reduced
•
Quality improved
•
Inspection time consumption reduced
References [1] Arun Kumar N., Srinivasan V., Krishna Kumar P., Analysing the strength of unidirectional fibre orientations under transverse static load, International Journal of Applied Engineering Research, v-9, i-22, pp-7749-7754, 2014. [2] Srinivasan V., Analysis of static and dynamic load on hydrostatic bearing with variable viscosity and pressure, Indian Journal of Science and Technology, v-6, i-SUPPL.6, pp-4777-4782, 2013. [3] Srinivasan V., Optimizing air traffic conflict and congestion using genetic algorithm, Middle - East Journal of Scientific Research, v-20, i-4, pp-456-461, 2014. [4] Praveen R., Achudhan M., Optimization of jute composite as a noise retardant material, International Journal of Applied Engineering Research, v-9, i-22, pp7627-7632, 2014. [5] Raja Kumar G., Achudhan M., Srinivasa Rao G., Studies on corrosion behaviour of borated stainless steel (304B) welds, International Journal of Applied Engineering Research, v-9, i-22, pp-7767-7772, 2014. [6] Ganeshram V., Achudhan M., Design and moldflow analysis of piston cooling nozzle in automobiles, Indian Journal of Science and Technology, v-6, i-SUPPL.6, pp-4808-4813, 2013. [7] Ganeshram V., Achudhan M., Synthesis and characterization of phenol formaldehyde resin as a binder used for coated abrasives, Indian Journal of Science and Technology, v-6, i-SUPPL.6, pp-4814-4823, 2013. [8] Achudhan M., Prem Jayakumar M., Mathematical modeling and control of an electrically-heated catalyst, International Journal of Applied Engineering Research, v9, i-23, pp-23013-, 2014.
27
Special Issue
[9] Anbazhagan R., Satheesh B., Gopalakrishnan K., Mathematical modeling and simulation of modern cars in the role of stability analysis, Indian Journal of Science and Technology, v-6, i-SUPPL5, pp-4633-4641, 2013. [10] Udayakumar R., Kaliyamurthie K.P., Khanaa, Thooyamani K.P., Data mining a boon: Predictive system for university topper women in academia, World Applied Sciences Journal, v-29, i-14, pp-86-90, 2014. [11] Kaliyamurthie K.P., Parameswari D., Udayakumar R., QOS aware privacy preserving location monitoring in wireless sensor network, Indian Journal of Science and Technology, v-6, i-SUPPL5, pp-4648-4652, 2013. [12] Kumar J., Sathish Kumar K., Dayakar P., Effect of microsilica on high strength concrete, International Journal of Applied Engineering Research, v-9, i-22, pp5427-5432, 2014. [13] Dayakar P., Vijay Ruthrapathi G., Prakesh J., Management of bio-medical waste, International Journal of Applied Engineering Research, v-9, i-22, pp-55185526, 2014. [14] Iyappan L., Dayakar P., Identification of landslide prone zone for coonoortalukusing spatialtechnology, International Journal of Applied Engineering Research, v-9, i-22, pp-5724-5732, 2014. [15] Swaminathan N., Dayakar P., Resource optimization in construction project, International Journal of Applied Engineering Research, v-9, i-22, pp5546-5551, 2014. [16] Swaminathan N., Sachithanandam P., Risk assessment in construction project, International Journal of Applied Engineering Research, v-9, i-22, pp-55525557, 2014. [17] Srividya T., Kaviya B., Effect on mesh reinforcement on the permeablity and strength of pervious concrete, International Journal of Applied Engineering Research, v-9, i-22, pp-5530-5532, 2014. [18] Sandhiya K., Kaviya B., Safe bus stop location in Trichy city by using gis, International Journal of Applied Engineering Research, v-9, i-22, pp-5686-5691, 2014. [19] Ajona M., Kaviya B., An environmental friendly self-healing microbial concrete, International Journal of Applied Engineering Research, v-9, i-22, pp-5457-5462, 2014. [20] Kumar J., Sachithanandam P., Experimental investigation on concrete with partial replacement of scrap rubber to granite stones as coarse aggregate, International Journal of Applied Engineering Research, v-9, i-22, pp-5733-5740, 2014. [21] Sachithanandam P., Meikandaan T.P., Srividya T., Steel framed multi storey residential building analysis and design, International Journal of Applied Engineering Research, v-9, i-22, pp-5527-5529, 2014. [22] Srividya T., Saritha B., Strengthening on RC beam elements with GFRP under flexure, International Journal
International Journal of Pure and Applied Mathematics
of Applied Engineering Research, v-9, i-22, pp-54435446, 2014. [23] Saraswathy R., Saritha B., Planning of integrated satellite township at Thirumazhisai, International Journal of Applied Engineering Research, v-9, i-22, pp-55585560, 2014. [24] Saritha B., Rajasekhar K., Removal of malachite green and methylene blue using low cost adsorbents from aqueous medium-a review, Middle - East Journal of Scientific Research, v-17, i-12, pp-1779-1784, 2013. [25] Saritha B., Ilayaraja K., Eqyaabal Z., Geo textiles and geo synthetics for soil reinforcement, International Journal of Applied Engineering Research, v-9, i-22, pp5533-5536, 2014. [26] Ilayaraja K., Krishnamurthy R.R., Jayaprakash M., Velmurugan P.M., Muthuraj S., Characterization of the 26 December 2004 tsunami deposits in Andaman Islands (Bay of Bengal, India), Environmental Earth Sciences, v66, i-8, pp-2459-2476, 2012. [27] Ilayaraja K., Ambica A., Spatial distribution of groundwater quality between injambakkamthiruvanmyiur areas, south east coast of India, Nature Environment and Pollution Technology, v-14, i-4, pp771-776, 2015. [28] Ilayaraja K., Zafar Eqyaabal M.D., Study of ground water quality in Cooum belt, Indian Journal of Science and Technology, v-8, i-32, pp--, 2015. [29] Sandhiya K., Ilayaraja K., Application of GIS for countering nuclear disaster, International Journal of Applied Engineering Research, v-9, i-22, pp-5561-5566, 2014. [30] Ambica A., Ground water quality characteristics study by using water quality index in tambaram area, Chennai, Tamil nadu, Middle - East Journal of Scientific Research, v-20, i-11, pp-1396-1401, 2014
28
Special Issue
29
30