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International Journal of Mechanical Engineering and Technology (IJMET)Volume 8, Issue 8, August 2017, pp.

Available online at http://www.iaeme.com/IJME

ISSN Print: 0976-6340 and ISSN Online: 0976

© IAEME Publication

TOOL LIFE PERFORMANCES

ROUGHNESS CHARACTERI

TURNING AUSTENISED

BEARING STEEL WITH C

Department of Mechanical Engineering, GITAM University

Department of Mechanical Engineering, GITAM University

ABSTRACT

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

in order to improve cutting efficiency, process at low

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

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

surface finishes with grinding quality.

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

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

calculation.

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

Performances and Surface Roughness Characterist

Quenched Bearing Steel with Ceramics and Hss

Engineering and Technology

http://www.iaeme.com/IJME

1. INTRODUCTION

Turning is a machining process in which a

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

Usually the term "turning" is reserved for the generation of

action, whereas this same essential cutting acti

holes, of one kind or another) is called "

IJMET/index.asp 140 editor@iaeme.com

International Journal of Mechanical Engineering and Technology (IJMET) 2017, pp. 140–147, Article ID: IJMET_08_08_16

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

6340 and ISSN Online: 0976-6359

Scopus Indexed

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.

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

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

f 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 surfa

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

AISI 52100 steel, Feed, Cutting Speed, Depth of cut, Cutting

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.

aeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=8

process in which a cutting tool, typically a non

tool path by moving more or less linearly while the work piece

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

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

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T&VType=8&IType=8

AND SURFACE

STICS WHEN

AND QUENCHED

ERAMICS AND HSS

Hyderabad, Telangana.

Hyderabad, Telangana.

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

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

1,2. The turning

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

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

, Feed, Cutting Speed, Depth of cut, Cutting force

K. Vijay Krishna Varma and V.S.V Sai Sumanth, Tool Life

ics when Turning Austenised and

International Journal of Mechanical

asp?JType=IJMET&VType=8&IType=8

, typically a non-rotary tool bit,

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

surfaces by this cutting

internal surfaces (that is,

". 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 an

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Table no 2– Observed Surface finish values

JOB NO. CUTTING

SPEED (rpm)

1 850

2 1300

3 1500

EXPERIMENT No -2

Cutting tool material

Work piece material

Feed

Cutting speed

Depth of cut

Table 3 Observed Surface

JOB NO. CUTTING

(rpm)

1 850

2 1300

3 1500

3. 3D MODEL

Figure 3 Final Model

JOB NO. SPINDLE SPEED

(rpm)

1 850

2 1300

3 1500

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics and Hss

IJMET/index.asp 142 editor@iaeme.com

Observed Surface finish values using HSS as cutting tool

CUTTING

SPEED (rpm)

FEED RATE

(mm/min)

DEPTH OF CUT

(mm)

850 500 0.2

00 350 0.3

1500 260 0.4

Ceramic

AISI bearing steel

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

850rpm, 1300rpm, 1500rpm

0.2mm, 0.3mm, 0.4mm

Observed Surface finish values using Ceramic as cutting tool

SPEED

(rpm)

FEED RATE

(mm/min)

DEPTH OF CUT

(mm)

500 0.2

00 350 0.3

1500 260 0.4

Final Model Figure no 4: 2D Drafting

Table 4 Cutting Forces

SPINDLE SPEED

(rpm)

FEED RATE

(mm/min)

DEPTH OF CUT

(mm)

500 0.2

00 350 0.3

1500 260 0.4

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

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using HSS as cutting tool

SURFACE

FINISH (Ra)

1.81

1.79

1.54

using Ceramic as cutting tool

DEPTH OF CUT Surface finish

(Ra)

1.56

1.27

0.92

Drafting

DEPTH OF CUT FORCE

(N)

130

195

260

K. Vijay Krishna Varma

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4.STRUCTURAL ANALYSIS

CERAMIC AND HSSTOOL

Sl.No Material

01 AISI 52100

02 CERAMIC

03 HSS

CUTTING TOOL MATERIAL

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

IJMET/index.asp 143 editor@iaeme.com

STRUCTURAL ANALYSIS OF TURNING AISI 52100 STEEL

TOOL

Table 5 Boundary Conditions:

Material Young’s Modulus

(MPa) Density (Kg/mm

3)

AISI 52100 210000 0.00000781

ERAMIC 380000 0.00000396

335000 0.00000435

CUTTING TOOL MATERIAL – CERAMIC (FORCE = 130N)

Figure 5 Total Deformation

Figure 6 Equivalent Stress

Figure 7 Equivalent Elastic Strain

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AISI 52100 STEEL WITH

Poisson’s Ratio

0.3

0.35

0.3

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics an

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FORCE - 195N

FORCE – 260N

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics and Hss

IJMET/index.asp 144 editor@iaeme.com

Figure 8: Total Deformation

Figure 9 Equivalent Stress

Figure 10 Equivalent Elastic Strain

Figure 11 Total Deformation

Figure 12 Equivalent Stress

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

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K. Vijay Krishna Varma

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CUTTING TOOL MATERIAL

FORCE -195 N

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

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

Figure 17 Total Deformation

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Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics an

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FORCE – 260 N

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

Quenched Bearing Steel with Ceramics and Hss

IJMET/index.asp 146 editor@iaeme.com

Figure 18 Equivalent Stress

Figure 19 Equivalent Elastic Strain

Figure 20 Total Deformation

Figure 21 Equivalent Stress

Figure 22 Equivalent Elastic Strain

Tool Life Performances and Surface Roughness Characteristics when Turning Austenised and

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

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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.