TMET (2015) 31-35 © STM Journals 2015. All Rights Reserved Page 31

Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print)

Volume 5, Issue 1

www.stmjournals.com

A Review on Machining of EN Series Steel

using Different Tools

Raman Brar1*, Manjeet Bohat

1, V.P.S. Kalsi

2, Sunil Dhingra

1

1Mechanical Engineering Department, U.I.E.T/Kurukshetra University, Kurukshetra

2Head-Metrology Division, CSIR-CSIO, Chandigarh, India

Abstract An elaborate study of review papers is conducted for the behavioral study of EN series steel,

while it is machined with optimum process parameters either conventional or nonconventional

machining processes. It is to benefit the Indian industry for manufacturing parts with better

quality and higher productivity. It is revealed from the literature that majority of medium

industry use nonconventional machines for generating intricate profiles. Present scenario of

industries look forward by quality product and high productivity. The study reveals different

machining processes like EDM, WEDM, TURNING, and MILLING. It will be beneficial for

medium-scale industries to sustain in the market by manufacturing better quality products

without losing time. Study of these papers revealed that very less work has been carried on

EN5 material using CNC milling machine.

Keywords: Surface roughness (SR), material removal rate (MRR), parameters optimization,

EN, Taguchi

*Author for Correspondence E-mail: ramanbrar272@gmail.com

INTRODUCTION EN steel series is basically medium carbon

steel which is used in manufacturing of

springs, guides, studs, axles etc. It is also used

in automotive, aerospace, tool & die making

industries due to its properties. It has many

grades—EN2, EN5, EN8 EN9, EN16, EN19,

EN24, EN31, EN33 and EN41 etc. In this

review paper, an elaborate study of different

machining process parameters on different EN

series materials has been done. After study of

20 research papers it was concluded that

optimization of machining parameters like

speed, feed, depth of cut, pulse on, pulse off,

peak current and servo voltage etc. are useful

for the industries. These parameters help the

industries for better quality product and also in

achieving production goal. Research work of

the industries is reduced by this type of

experiments. It is also useful for academic

purpose in its optimization utilization in

structural design. Machine used in these

process were EDM, WEDM, TURNING,

MILLING, DRILLING and BORNING etc.

Following results were obtained from different

machines after the study of review papers. In

the EDM machining, there were machining

parameters like pulse on, pulse off, current and

bed speed. In this process, optimized values of

process parameters were evaluated by

conducting experiment. Design of experiment

was done by Minitab software. Result can be

evaluated by many methodologies like

Taguchi technique, ANOVA technique, RSM

etc. Results showed that peak current and

pulse on time increases with increase in MRR

and decreases by jet pressure. In the milling

process, different process parameters were

considered such as speed, feed, depth of cut,

tool types and coolant etc. Response

parameters taken were MRR and surface

roughness (SR). These were evaluated by

different methodologies after the evaluation of

results. Results showed that MRR and SR

increases with increase in cutting speed and

feed. After a certain limit, SR decreases with

increase in cutting speed and feed. In case of

WEDM, process parameters considered were

wire tensions, pulse width, wire electrodes,

pulse off time, pulse on time, and current etc.

Response parameters considered were SR and

material removal rate (MRR). Generally

results shows that SR and MRR are affected

when pulse on time is the most significant

factor.

Review study of EN steel Brar et al.

TMET (2015) 31-35 © STM Journals 2015. All Rights Reserved Page 32

LITERATURE REVIEW More than 20 research papers were reviewed

and many machining parameters has been

revealed. Some of them are listed below:

Amit et al. [1] investigated the effect of

machining parameters on EN-5 steel using

EDM drilling. Experiment was designed with

the help of Taguchi method. The significant

factors affecting the machining performance

were peak current, pulse on time and jet

pressure. Response parameters taken were

MRR. It was observed that MRR increases

with increase in peak current and pulse on

time and decreases by jet pressure. As peak

current increases MRR also increases and

MRR is decreased by increase in jet pressure.

Ashok Raj et al. [2] revealed the optimization

of process parameters of EN8 using Taguchi

methodology. In this investigation, he

observed the machining performance with

various cutting speed, feed and depth of cut

using side and face milling. Orthogonal array

was identified by Taguchi technique. After the

experimental investigation, result showed that

cutting speed was statistically significant

factor influencing SR.

Moshat et al. [3] investigated the optimization

of CNC end milling process parameters using

PCA-based Taguchi method. In this

investigation, main purpose was to provide

good surface finish and high MRR of

aluminum. Three process parameters such as

spindle speed, feed rate and depth of cut were

taken. Response features used were SR and

MRR. By using Taguchi methodology, a

relationship between control factor and

responses was established by means of

nonlinear regression analysis resulting in a

valid mathematical model.

Vikas et al. [4] investigated the effect of

machine process parameters on MRR for

EN19 & EN41 materials using die sinking

EDM machine. Control factors considered

were pulse on time, pulse off time, discharge

current and voltage; while MRR was

considered as response variable. By using

Taguchi method, it has been considered that

discharge current has more effect on MRR as

compared to others variables.

Annamalai et al. [5] experimentally achieved

the maximum MRR and minimum electrode

tool wear of EDM machine on EN24 material

using response surface modelling. Machining

parameters taken were peak current, pulse on

time and pulse off time. Investigation showed

that when peak current and pulse on time

increases, MRR, EWR and SR increases. Pulse

off time has no effect on it.

Dhole et al. [6] revealed the optimization of

milling machine process parameters using

Taguchi design approach. In this study, input

parameters taken were cutting speed, feed rate,

depth of cut and tool materials and the

response variable was cutting force. L18

orthogonal array was taken on EN33 materials.

It was observed that cutting force has major

influence on cutting speed and feed rate. When

cutting speed increases cutting force

decreases. But when feed and depth of cut

increases, cutting force also increases.

Maiyar et al. [7] reported the machining of

Inconel 718 super alloy by using End Milling

process. Taguchi-based grey relational

analysis method was used. Cutting velocity,

feed and depth of cut was used as control level

and SR and MRR was used as response. This

study showed that cutting velocity has more

influence on SR and MRR.

Kapoor and Singh [8] studied the results of the

effect of cryogenic treated brass wire electrode

on the surface of an EN31 steel machined by

WEDM. Full factorial experimental design

strategy was used in the experimentation.

Three process parameters, namely type of wire

electrode (untreated and cryogenic treated

brass wire electrodes), pulse width, and wire

tension has been considered. The process

performance was measured in terms of SR.

type of wire, pulse width and wire tension

significantly affecting the SR. In WEDM,

ANOVA results indicated that all the process

parameters have significant effect on SR.

Shivade et al. [9] investigated the optimization

of SR and tool tip temperature on EN8

material using turning process. In this process,

L9 orthogonal array was designed using

Taguchi technique. Speed and feed rate was

taken as machining parameters and an

Trends in Mechanical Engineering & Technology

Volume 5, Issue 1

ISSN: 2231-1793(online), ISSN: 2347-9965(print)

TMET (2015) 31-35 © STM Journals 2015. All Rights Reserved Page 33

optimized combination of input variable was

found by using ANOVA technique.

Noorani et al. [10] reported the improving SR

using CNC milling machine with aluminum

alloy 6061 samples due to process parameter

variation. Spindle speed, depth of cut, feed and

tool size were taken as control factors.

Classical method of design of experiment was

chosen for research. After the experimental

analysis, two factors were found highly

responsible for SR, i.e., feed rate and tool size.

Most SR was found when feed rate was high

with high depth of cut and low spindle speed.

Chaudary and Rampal [11] investigated the

effect of process parameters of WEDM on

EN5 materials using RSM technique. In this

process, control factors wers taken as pulse on,

pulse off, peak current, servo voltage; and

MRR was taken as response variable. For

designing the experiment, central control

design methodology was used. Experimental

result showed that Ton was the most

significant factor affecting MRR.

Brahmnhatt et al. [12] studied the optimization

parameters on EN9 steel for turning process

using Taguchi method. In this experiment,

spindle speed, feed and depth of cut were

taken as input variables. SR and MRR were

taken as output variables. By using ANOVA

technique, the parameters affecting response

variables was analyzed and a combination of

optimized values was evaluated.

Rawangwong et al. [13] devised an approach

of face milling machining parameter on AA

7075 semi-solid using carbide tool. In this

research, spindle speed, feed and depth of cut

was taken as control level. Result revealed that

the factors affecting SR were feed rate and

cutting speed, while depth of cut unaffected

the SR. High speed and low feed gave low

roughness. Speed and feed rate were the most

responsible to tool wear.

Saini and Choudhary [14] researched on

machining parameter optimization of SS202

steel by using Taguchi method. In this

investigation, input machining parameters

were considered such as cutting speed, feed

and depth of cut. Response factor was taken as

SR. The tool used for face milling operation

was carbide inserted face milling cutter. From

the investigation, it was found that at 2500

rpm spindle speed, 200 mm/min feed and 0.2

mm depth of cut gave optimum level of input

parameter.

Pang et al. [15] researched on optimizing

machining parameter on CNC milling with

(HNT/AL/EP) composite. An orthogonal array

was designed using Taguchi method. In this

research, Taguchi gave the best optimal result

of lower SR.

Rashid and Lani [16] applied artificial

intelligence method to predict SR for CNC

milling. Because conventional trial and error

method was time consuming. In this

experiment, the input variables were speed,

feed and depth of cut. Mathematical model

was developed by RSM technique and ANN

technique. Orthogonal array was taken as L27.

Analysis of variance shows that feed rate has

high influence on SR rather than others

parameters.

Zhang et al. [17] optimized surface quality in a

CNC face milling operation. Experiment was

designed by L9 orthogonal array with the help

of Taguchi design and ANOVA technique was

used to identify significant factors affecting

SR. Aluminum blocks as a work piece of 19.1

X 38.1 X 76.2 mm was used. Results showed

that feed rate and spindle speed has high effect

on SR than depth of cut.

Singh and Kumar [18] investigated the

optimization of bending strength in EN24

steel. Taguchi method was used for designing

the experiment. Machining parameters were

analyzed under varying currents (24.8 A, 29.2

A, 38.5 A), weld time (5 sec, 10 sec, 15 sec).

Results showed that time was an important

factor than current for bending strength. When

time tends to increase, the bending strength

also increases for maximum. Bending strength

current should be at maximum level.

Reddy et al. [19] studied the optimization of

process parameters of CNC end milling on

pre-hardened steel (P20) using RSM and

genetic algorithm. To achieve surface finish

this experiment should be conducted with

Review study of EN steel Brar et al.

TMET (2015) 31-35 © STM Journals 2015. All Rights Reserved Page 34

orthogonal array L50. Machining parameters

considered were nose radius, cutting speed,

feed and depth of cut. RSM interact with GA

to find out the machining parameters values.

Result showed that SR reduced by 44.22%.

CONCLUSIONS From the above literature review, it can be

concluded that more work is required on EN

series materials using EDM and WEDM.

Optimized values of these machining

parameters have been evaluated for better

quality product and high productivity. Use of

many methodologies like Taguchi

methodology, ANOVA methodology etc. for

optimization of process parameters give

improved result in the industry. Study of

papers revealed that very less work has been

initiated in conventional machining. Research

work should be encouraged for optimizing the

process parameters for machining EN5 steel.

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Cite this Article Brar R, Bohat M, Kalsi VPS, Dhingra S.

A Review on Machining of EN Series

Steel Using Different Tools. Trends in

Mechanical Engineering and

Technology. 2015; 5(1): 31–35p.