MANUFACTURING OF LATHE TOOL FROM SCRAP

© 2020 JETIR August 2020, Volume 7, Issue 8 www.jetir.org (ISSN-2349-5162)

JETIR2008265 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 1996

MANUFACTURING OF LATHE TOOL FROM

SCRAP

1Justin Prasad, 2Nevin Nelson,3Allwyn S D’cruz,4Aswin Lal M,5Athul Joy

1345Final year B-Tech Students, 2Assistant Professor

Department of Mechanical Engineering.

Bishop Jerome Institute, Kollam, Kerala, India.

Abstract :The measurement of cutting forces in metal cutting is essential to estimate the power requirements, to design the cutting

tool and to analyse machining process for different work and tool material combination. In our project a new lathe tool is made

from scraps of medium carbon steel by adding SiC as additive. The metal scarp undergoes ball milling process. By stir casting

process additive is added and the metal is obtained in a rectangular block. This rectangular block is machined into lathe tool.

Different tests are done on the tool for different parameters

IndexTerms: Composite, Matrix, Mould, Manufacturing, Fabrication.

1. INTRODUCTION

1.1 Composite Material:

Composite material is a macroscopic combination of two or more distinct materials, having a recognizable interface

between them. Composites are used not only for their structural properties, but also for electrical, thermal, and environmental

applications. Modern composite materials are usually optimized to achieve a particular balance of properties for a given

range of applications. The composites are heterogeneous materials, which is an important feature compared for instance to the

metal homogeneous plastics. There are many kinds of failure and damage modes in the composite structures. One of them is the

interlaminar fracture known as delamination, which is, at the same time one of the most important failure mode. Delamination

growth remains a critical failure mode in laminated composite structures. The interlaminar fraction of composite material has

been very intensively investigated. The delamination means degradation between adjacent plies of material. A fibre-reinforced

composite (FRC) is a high-performance composite material made up of three components - the fibres as the discontinuous or

dispersed phase, the matrix acts as the continuous phase, and the fine inter-phase region or the interface. The matrix is basically a

homogeneous and monolithic material in which a fibre system of a composite is embedded. It is completely continuous. The

matrix provides a medium for binding and holding reinforcements together into a solid. It offers protection to the reinforcements

from environmental damage, serves to transfer load, and provides finish, texture, colour, durability and functionality.

1.2 Types of Composite Matrix Materials

There are three main types of composite matrix materials: Ceramic matrix - Ceramic matrix composites (CMCs) are a subgroup

of composite materials. They consist of ceramic fibres embedded in a ceramic matrix, thus forming a ceramic fibre reinforced

ceramic (CFRC) material. The matrix and fibres can consist of any ceramic material. CMC materials were designed to overcome

the major disadvantages such as low fracture toughness, brittleness, and limited thermal shock resistance, faced by the traditional

technical ceramics.

1.3 Metal Matrix Composite

A metal matrix composite (MMC) is composite material with at least two constituent parts, one being a metal. The other material

may be a different metal or another material, such as a ceramic or organic compound. When at least three materials are present, it

is called a hybrid composite. An MMC is complementary to cement. Composition MMCs are made by dispersing a reinforcing

material into a metal matrix. The reinforcement surface can be coated to prevent a chemical reaction with the matrix the

reinforcement material is embedded into the matrix. The reinforcement does not always serve a purely structural task (reinforcing

the compound), but is also used to change physical properties such as wear resistance, friction coefficient, or thermal

conductivity. The reinforcement can be either continuous, or discontinuous. Discontinuous MMCs can be isotropic, and can be

worked with standard metalworking techniques, such as extrusion, forging or rolling. In addition, they may be machined using

conventional techniques, but commonly would need the use of polycrystalline diamond tooling (PCD). Continuous reinforcement

uses monofilament wires or fibres such as carbon fibre or silicon carbide.

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2. METHOD

3. MATERIALS SELECTION

3.1 Steel Scrap:Scrap consists of recyclable materials left over from product manufacturing and consumption, such as parts of

vehicles, building supplies, and surplus materials. Unlike waste, scrap has monetary value, especially recovered metals, and non-

metallic materials are also recovered for recycling. Steel scrap consists of discarded steel or steel products, generally segregated

by composition and size or ‘grade’ suitable for melting. There are three main types of scrap which are used by the steel industry

as feed stock. These are (i) internal scrap, (ii) prompt scrap, and (iii) obsolete scrap. Internal scrap is also known as revert or home

scrap. It refers to the reject metal within the steel plant which gets generated during steel making, steel casting and steel finishing

activities within the steel plant. Prompt scrap is also known as process scrap and it is the waste generated during the product

manufacturing by the steel plant’s customers i.e. the manufacturing industries. Obsolete scrap consists of that scrap which is

recovered from discarded industrial and consumer items. Steel scrap is considered to be free of alloys if the residual content

of the following elements contained in steel do not occur at levels consistent with the purposeful creation of an alloy steel.

Residual level of elements contained within the scrap shall not exceed chromium 0.20 %, nickel 0.45 %, manganese 1.65 % and

molybdenum 0.10 %. The combined residuals other than manganese shall not exceed a total of 0.60 %. A scrap is considered to

be off grade if it fails to meet (i) applicable size limitations, (ii) applicable requirements for the type of scrap, and (iii) applicable

requirement with respect to the scrap quality.

3.2 Steel Scrap Processing

Processing of steel scrap involves size reduction, cleaning, sorting, shredding, pressing, shearing and crushing. Steel scrap

processing also results into increasing of the density of the scrap mass.

Pressing – Pressing means using a baler to press thin sheet steel scrap into bales. Pressing is also used e.g. to reduce the volume of

junk cars (logging). The purpose of pressing is in fact to reduce the volume of the light scrap sheet metal and to increase the

volume weight to a weight suitable for the electric steel making. Moreover, pressing can also reduce transport costs and facilitate

storage. Pressing can also include briquetting, i.e. pressing lathe chips into briquettes.

Crushing – Crushing is done with various metal crushers. Crushing is used in the processing of thin or dirty sheet steel scrap and

junk cars. The purpose of crushing is to break down the steel scrap metal into smaller pieces.

Shearing – Shearing means the cutting and pressing of thicker scrap steel. Shearing takes place in big, guillotine-like scrap shears.

Steel beams and miscellaneous scrap are cut into – 60 cm or – 80 cm pieces. Shearing increases the bulk density of the scrap,

making it easier to handle and portion out.

Shredding – Shredders incorporate rotating magnetic drums to extract iron and steel from the mixture of metals and other

materials.

Sorting – Sorting is the process of separating the different metals and other materials. This is done using magnets, eddy current

separators, screening, blowing/suction (air classifier), flotation (gravitational separation), optical separation and manual

separation.

MATERIALS SELECTION

PURCHASE AND COLLECTION OF

RAW MATERIALS

FABRICATION PROCESS

MECHANICAL TESTING

COMPARISON OF RESULTS




Figure.1 Steel scraps processing

4. SILICON CARBIDE

Silicon Carbide is the only chemical compound of carbon and silicon. It was originally produced by a high temperature electro-

chemical reaction of sand and carbon. Silicon carbide is an excellent abrasive and has been produced and made into grinding

wheels and other abrasive products for over one hundred years. Today the material has been developed into a high quality

technical grade ceramic with very good mechanical properties. It is used in abrasives, refractories, ceramics, and numerous high-

performance applications. The material can also be made an electrical conductor and has applications in resistance heating, flame

igniters and electronic components. Structural and wear applications are constantly developing.

4.1 General Silicon Carbide Information

Silicon carbide is composed of tetrahedral of carbon and silicon atoms with strong bonds in the crystal lattice. This produces a

very hard and strong material. Silicon carbide is not attacked by any acids or alkalis or molten salts up to 800°C. In air, SiC forms

a protective silicon oxide coating at 1200°C and is able to be used up to 1600°C. The high thermal conductivity coupled with low

thermal expansion and high strength give this material exceptional thermal shock resistant qualities. Silicon carbide ceramics with

little or no grain boundary impurities maintain their strength to very high temperatures, approaching 1600°C with no strength loss.

Chemical purity, resistance to chemical attack at temperature, and strength retention at high temperatures has made this material

very popular as wafer tray supports and paddles in semiconductor furnaces. The electrical conduction of the material has led to its

use in resistance heating elements for electric furnaces, and as a key component in thermistors (temperature variable resistors) and

in varistors (voltage variable resistors).

5. PURCHASE AND COLLECTION OF RAW MATERIALS

5.1 Materials Collected:

Steel Scraps collected from the lathe, CNC, milling, etc., machines during the operations of boring, taper turning, face turning and

from other operations about 16kg

Silicon carbide Powder Purchased from Micro Fine Chemicals – 250 Grams.

Figure.3 Steel Scrap Figure.2 Silicon Carbide




6. MANUFACTURING METHOD

6.1 Ball Milling & Sand Casting- Medium Carbon Steel

The ball mill is a key piece of equipment for grinding crushed materials, and it is widely used in production lines for powders

such as cement, silicates, refractory material, fertilizer, glass ceramics, etc. as well as for ore dressing of both ferrous and non-

ferrous metals. The scrap collected is about 1cm thick and 5-8 cm long. Therefore ball mill is used for crushing the scrap material

i.e medium carbon steel. A ball mill, a type of grinder, is a cylindrical device used in grinding (or mixing) materials like ores,

chemicals, ceramic raw materials and paints. Ball mills rotate around a horizontal axis, partially filled with the material to be

ground plus the grinding medium. Different materials are used as media, including ceramic balls, flint pebbles and stainless steel

balls. An internal cascading effect reduces the material to a fine powder. Industrial ball mills can operate continuously fed at one

end and discharged at the other end. Large to medium-sized ball mills are mechanically rotated on their axis, but small ones

normally consist of a cylindrical capped container that sits on two drive shafts (pulleys and belts are used to transmit rotary

motion). A rock tumbler functions on the same principle.

Figure.4: A section cut thru of ball mills

6.2 Cutting Tool Testing

6.2.1 Three point bending Test- UTM

The three-point bending flexural test provides values for the modulus of elasticity in bending, flexural stress, flexural strain and

the flexural stress–strain response of the material. This test is performed on a universal testing machine (tensile testing machine or

tensile tester) with a three-point or four-point bend fixture.The main advantage of a three-point flexural test is the ease of the

specimen preparation and testing. However, this method has also some disadvantages: the results of the testing method are

sensitive to specimen and loading geometry and strain rate.

Figure.5: Three-point flexural testing

6.2.2 Tensile test- Extensometer-UTM

The specimen is placed in the Universal Testing machine between the grips and an extensometer if required can automatically

record the change in gauge length during the test.




6.2.3 Surface hardness- Vickers Hardness Test

The Vickers test is often easier to use than other hardness tests since the required calculations are independent of the size of the

indenter, and the indenter can be used for all materials irrespective of hardness. The basic principle, as with all common measures

of hardness, is to observe a material's ability to resist plastic deformation from a standard source. The unit of hardness given by

the test is known as the Vickers Pyramid Number (HV) or Diamond Pyramid Hardness (DPH). The hardness number is determined by the load over the surface area of the indentation and not the area normal to the force, and is therefore not pressure.

6.2.4 Impact Test- Charpy test

The apparatus consists of a pendulum of known mass and length that is dropped from a known height to impact a notched

specimen of material. The energy transferred to the material can be inferred by comparing the difference in the height of the

hammer before and after the fracture (energy absorbed by the fracture event).The notch in the sample affects the results of the

impact test,thus it is necessary for the notch to be of regular dimensions and geometry. The size of the sample can also affect

results, since the dimensions determine whether or not the material is in plane strain. This difference can greatly affect the

conclusions made.

6.2.5 Microstructure Test

Examination of the microstructure of a material provides information used to determine if the structural parameters are within

certain specifications. The analysis results are used as a criterion for acceptance or rejection.Microstructural examination is

generally performed using optical or scanning electron microscopes to magnify features of the material under analysis. The

amount or size of these features can be measured and quantified, and compared to acceptance criteria. These examinations are

often used in failure analysis to help identify the type of material in question and determine if the material received the proper

processing treatments.

7. FABRICATION PROCESS

7.1 Sand Casting Method:

Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made

of nearly any alloy. Because the sand mould must be destroyed in order to remove the part, called the casting, sand casting

typically has a low production rate. The sand casting process involves the use of a furnace, metal, pattern, and sand mold. The

metal is melted in the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the pattern. The

sand mold separates along a parting line and the solidified casting can be removed. The steps in this process are described in

greater detail in the next section.

8. MACHINING:

Machining is used to introduce features that cannot be produced during the casting process. This is due to the very small

tolerances of the design dimensions. Machining takes place once any fettling or heat treatment has been completed but before any

finishing processes, such as anodising or painting. Machining is carried out by computer numerical control (CNC).

8.1 Turning

In turning, carbide or ceramic cutting tools are used to create a smooth finish on the casting.The component is positioned in a

chucking (turning) fixture and rotated using either a vertical or horizontal machine. Using the tools, any unwanted material can be

removed from the inside and outside of the casting to produce turned bores (holes) and diameters to close tolerances, with a high

standard of finish.

Figure 6: Sand Casting

Figure 7: Image of Sand Casting




8.2 Milling

In milling, the component is securely clamped to the machine table. The cutting tools, which use changeable carbide or ceramic

inserts, move and rotate at optimum speed across the work piece to generate various features on the face of the casting. This can

be carried out on a horizontal or vertical axis.

8.3 Surface grinding

Surface grinding is used to produce a precision flat finish. The component is secured on a magnetic plate or, with non-ferrous

castings, a holding fixture. The outside edges of the castings are ground using a carborundumgrinding wheel, which revolves at a

rapid speed to produce the required finish.

9. INSPECTION:

The final stage of the process is designed to check that the machining work meets the specified criteria. Casting inspection is

carried out using automated equipment and probes during the machining process and post manufacture.

Figure.8: Image of Rectangular Block Figure.9: Image of the Specimens before Testing

10. MECHANICAL TESTING

10.1 Impact Test (Izod)

Izod impact testing is an ASTM standard method of determining the impact resistance of materials. A pivoting arm is raised to a

specific height (constant potential energy) and then released. The arm swings down hitting the sample, breaking the specimen.

The energy absorbed by the sample is calculated from the height the arm swings to after hitting the sample. A notched sample is

generally used to determine impact energy and notch sensitivity.

Impact tests are used in studying the toughness of material. A material's toughness is a factor of its ability to absorb energy during

plastic deformation. Brittle materials have low toughness as a result of the small amount of plastic deformation that they can

endure. The impact value of a material can also change with temperature. Generally, at lower temperatures, the impact energy of a

material is decreased. The size of the specimen may also affect the value of the Izod impact testbecause it may allow a different

number of imperfections in the material, which can act as stress risers and lower the impact energy.

Figure.10 Impact Testing Machine




11. TENSILE TEST

Tensile testing, is also known as tension testing, is a fundamental materials science test in which a sample is subjected to a

controlled tension until failure. Properties that are directly measured via a tensile test are ultimate tensile strength, maximum

elongation and reduction in area. From these measurements the following properties can also be determined: Young's modulus,

Poisson's ratio, yield strength, and strain-hardening characteristics. Uniaxial tensile testing is the most commonly used for

obtaining the mechanical characteristics of isotropic materials. For anisotropic materials, such as composite materials and textiles,

biaxial tensile testing is required.

11.1 Tensile specimen

A tensile specimen is a standardized sample cross-section. It has two shoulders and a gage (section) in between. The shoulders are

large so they can be readily gripped, whereas the gauge section has a smaller cross-section so that the deformation and failure can

occur in this area.

11.2 Equipment

The most common testing machine used in tensile testing is the universal testing machine. This type of machine has two

crossheads; one is adjusted for the length of the specimen and the other is driven to apply tension to the test specimen. There are

two types: hydraulic powered and electromagnetically powered machines.

Alignment of the test specimen in the testing machine is critical, because if the specimen is misaligned, either at an angle or offset

to one side, the machine will exert a bending force on the specimen. The strain measurements are most commonly measured with

an extensometer, but strain gauges are also frequently used on small test specimen or when Poisson's ratio is being measured.

3. VICKERS HARDNESS TEST

It was decided that the indenter shape should be capable of producing geometrically similar impressions, irrespective of size; the

impression should have well-defined points of measurement; and the indenter should have high resistance to self-deformation.

A diamond in the form of a square-based pyramid satisfied these conditions. Accordingly, loads of various magnitudes are applied

to a flat surface, depending on the hardness of the material to be measured. The HV number is then determined by the ratio F/A,

where F is the force applied to the diamond in kilograms-force and A is the surface area of the resulting indentation in square

millimeters. A can be determined by the formula.

A=𝒅𝟐

𝟐𝐬𝐢𝐧𝟏𝟑𝟔°

𝟐

which can be approximated by evaluating the sine term to give,

𝑨 ≈𝐝𝟐

𝟏.𝟒𝟖𝟒𝟒

where d is the average length of the diagonal left by the indenter in millimeters. Hence,

HV= 𝐅

𝐀≈

𝟏.𝟖𝟓𝟒𝟒𝑭

𝒅𝟐

where F is in kgf and d is in millimeters.

The corresponding units of HV are then kilograms-force per square millimeter (kgf/mm²). In the above equation, "F" could be in

N and "d" in mm, giving HV in the unit of MPa. To calculate Vickers hardness number (VHN) using SI units one needs to

convert the force applied from newtons to kilogram-force by dividing by 9.806 65 (standard gravity). This leads to the following

equation:

HV≈ 𝟎. 𝟏𝟖𝟗𝟏𝑭

𝒅𝟐

(1)

(2)

(3)

Figure.11 Tensile Testing Machine

( 4 )


https://en.wikipedia.org/wiki/Diamond

https://en.wikipedia.org/wiki/Kilogram-force

https://en.wikipedia.org/wiki/Kilogram-force

https://en.wikipedia.org/wiki/Standard_gravity



where F is in N and d is in millimeters. A common error is that the above formula to calculate the HV number does not result in a

number with the unit Newton per square millimeter (N/mm²), but results directly in the Vickers hardness number (usually given

without units), which is in fact kilograms-force per square millimeter (kgf/mm²).

3. FLEXURAL TEST

The three point bending flexural test provides values for the modulus of elasticity in bending Ef, flexural stress sigma f, flexural

strain epsilon f and the flexural stress-strain response of the material. The main advantage of a three-point flexural test is the ease

of the specimen preparation and testing. However, this method has also some disadvantages: the results of the testing method are

sensitive to specimen and loading geometry and strain rate.

.

Figure.12: Test Fixture on Universal Testing Machine for Three points flex test

3. MICROSTUCTURE TEST

14.1 Performing Microstructural Examination

Examination of the microstructure of a material provides information used to determine if the structural parameters are within

certain specifications. The analysis results are used as a criterion for acceptance or rejection.Microstructural examination is

generally performed using optical or scanning electron microscopes to magnify features of the material under analysis. The

amount or size of these features can be measured and quantified, and compared to acceptance criteria. These examinations are

often used in failure analysis to help identify the type of material in question and determine if the material received the proper

processing treatments. Metallurgical examinations may evaluate.

14.2 The Process

Selecting a representative test sample to properly characterize the microstructure or the features of interest is a very important first

step. Test samples are carefully sectioned to avoid altering or destroying the structure of the materials. After the test sample is

sectioned to a convenient size, it is mounted in a plastic or epoxy material to facilitate handling and the grinding and polishing

steps. Mounting media must be compatible with the sample with respect to hardness and abrasion resistance. Mounting involves

putting the sample in a mould and surrounding it with the appropriate powder. When the mould is heated and pressurized at the

correct levels, setting or curing of the media occurs. The mounted sample is removed from the mould. Grinding follows mounting

to remove the surface damage that occurred during the sectioning step and to provide a flat surface. The polishing step removes

the last thin layer of the deformed metal. It leaves a properly prepared sample. The final step that might be used is etching to show

the microstructure of the test sample. This step reveals features such as grain boundaries, twins and second phase particles not

seen in the unetched sample.

RESULTS

TENSILE TEST RESULTS

SPECIMEN TENSILE(Mpa)

Steel scraps 178.73

Steel scraps + 5% Silicon Carbide 183.23

Table 1: Tensile Test Result


https://en.wikipedia.org/wiki/Kilograms-force



FLEXURAL TEST RESULT

HARDNESS TEST RESULTS

IMPACT TEST RESULTS

MICROSTUCTURE TEST RESULTS:

At the end of this project we manage to manufacture a turning tool out of industrial waste which constitutes medium carbon

steel.the tool can be used for machining materials having hardness less than 293 (HV).The tool can be used to machine materials

such as Aluminium,Plastic,Polyester, Teflon, Nylon,Lead,Tin.

SPECIMEN FLEXURALSTENGTH (MR)

Steel scraps 28.15


SPECIMEN HARDNESS (HV)

Steel scrap 290.4

Steel scrap +5% Silicon Carbide 293

SPECIMEN IMPACT VALUE (J)

Steel scraps 3.5


Figure.13: Micro-structure result without adding

SiC

Figure.14: Micro-structure result after adding

SiC

Table 2: Flexural Test Result

Table 4: Impact Test Result

Impact Test Result

Table 3: Hardness Test Result




Test Medium

Carbon Steel

Manufactured

Tool(Scrap

with SiC)

Tensile

Strength

483 MPa 183.23 MPa

Hardness 125HV 293 HV

Impact 9J 3.5 J

Flexural

Strength

36 MR 29.79 MR

CONCLUSIONS

From our project work we conclude that we made a tool out of metal scrap which is of Medium Carbon steel and use it for

machining process. After the production the materials were subjected to compression, three points bending and hardness tests. 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. The surface roughness is significantly influenced by the feed rate, the insert radius, and depth of cut. The surface

roughness increases with the increase of the feed rate, decreases with the increase of insert radius and increases with increase in

depth of cut. The effect of cutting speed is less significant, the surface roughness slightly decreases with the increase cutting

speed, respectively. The cutting force is significantly influenced (at a 95% confidence level) by feed rate, depth of cut, while

cutting speed and insert radius have a small influence. The cutting force increases with the increase of feed rate and depth of cut,

respectively .The mechanical properties of the composite materials mainly depends on mechanical response of scrap materials

added .It is concluded that Medium carbon steel constituents creates a positive effect on ductility when tested under compression.

At the end of the project we will use the newly made tool to find the different cutting forces.

REFERENCES

[1] Thangarasu S.K, Shankar.S, Tony Thomas (2018), Prediction of Cutting Force in Turning Process-an Experimental

Approach.

[2] Kulecki.P, Lichańska.E,(2017), The Effect Of Powder Ball Milling On The Microstructure And Mechanical Properties

Of Sintered Fe-cr-mo-mn-(cu) STEEL, Powder Metallurgy Progress, 17(2) 082-092

[3] HakanBurakKaradag, Tuba Bahtli, Memduh Kara (2016), The Recycling of Steel and Brass Chips to Produce

Composite Materials via Cold Pressing and Sintering,(IJES),5(5) 01-06.

[4] Naveen Kumar., M.V.Varalakshmi, Raveendra (2015)Measurement of Cutting Forces While Turning Different Materials

by Using Lathe Tool Dynamometer with Different Cutting Tool Nomenclature,4(7) 6070-6077

[5] Pramod Kumar N,Avinash N V ,Sudheer K and Umashankar K S, (2014), Thermal and Tool Wear Studies On Mild Steel

Turning.

[6] MuammerNalbant, HasanGokkaya, and IhsanToktas¸(2007),Comparison of Regression and Artificial Neural Network

Models for Surface Roughness Prediction with the Cutting Parameters in CNC Turning.

[7] Indrajith Mukharji, Pradip Kumar Ray (2006), A Review of Optimisation Techniques In Metal Cutting process.

E. Biles, James J. Swain,(1980), Optimization and industrial experimentation.

Figure.15: The Manufactured Turning Tools

Table 5: Comparison between Medium Carbon Steel and Manufactured Tool


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MANUFACTURING OF LATHE TOOL FROM SCRAP