Tribological Studies of Laser Textured Tool Inserts in ... Sample ppt.pdf · the area. However here relevant 10 papers have ... 380 in/min, 1500 rpm Depth of cut= 3 mm, Dry and wet

Presentation by:

P. Deepak Kumar (1209540038)

Ashish Bhatt (1209540012)

Prashant Kumar Rajput (1209540043)

(Group No.-7)

Supervisor:

Mr. Umesh Yadav

Assistant Professor

Tribological Studies of Laser Textured

Tool Inserts in Turning Operation

1

Outline of presentation

1. Background

2. Literature review

3. Motivation for the work

4. Objective of project

5. Methodology adopted

6. Results

7. Conclusions drawn

8. References

2

1. Background

Manufacturing is a very important component of

any engineering realization. It involves providing

the different shapes, sizes and cross sections to the

components of the products/systems.

Source: Industrial Development Report by United Nation

Industrial Development Organization (2013) 3

…Background continued

It is worth noting here that high percent of GDP of

many nations comes from the manufacturing

sector.

4

Source: Euro-monitor International from national statistics/UN/OECD (2013)

• Manufacturing sector also provides maximum

jobs to the people. This is also one of the

reasons for launching the “Make in India”

programme by our prime minister in 2014.

• For large scale manufacturing in any country,

there is a requirement for efficient and quality

machining for its sustainability. Thus, there is

need for in-depth research in manufacturing

processes for making it more energy efficient

with better finished quality.

5

• It is worth noting here that setting up of large

manufacturing industries for boosting the GDP

and providing the employment can harm the

nature through its emissions and effluent

disposals.

• Thus a need arises for development of energy

efficient green manufacturing for protecting the

environment. Even a small energy saving per

ton of manufacturing adds up to huge sums

resulting in money and resource savings in eco-

friendly manner. 6

Literature Review

Literature survey has been carried out for

exploring the existing ways of making the

manufacturing an efficient and eco-friendly

process.

About 15 researcher papers have been read in

the area. However here relevant 10 papers have

been reviewed and discussed. The gist of the

review are being presented as follows:

7

literature review continued…

8

Researchers,

Pub. year,

and Journal

name

Machining

type,

parameters

Material of tool

and work piece

Details of

investigation

Observation/

Finding

Sugihara and

Enomoto,

(2009),

Precision

Engg.

Face milling,

Feed rate=0.12

mm/rev,

Cutting speed=

380 in/min,

1500 rpm

Depth of cut= 3

mm, Dry and

wet machining

Cemented carbide,

Aluminum: A5052

Nano/micro

textured surfaces

on tool were

created to study

anti-adhesive

effect

Significant

improvement in

anti-

adhesiveness

and lubricity


9

Researchers,

Pub. year,

and Journal

name

Machining

type,

parameters

Material of tool and

work piece

Details of

investigation

Observation/

Finding

Sugihara and

Enomoto,

(2010), CIRP

Annals-

Manufacturing

Technology

Face milling,

Feed rate=0.12

mm/rev,

Cutting speed=

380 in/min,

1500 rpm

Depth of cut= 3

mm

DLC-coated cemented

carbide tool with

grooves parallel to

cutting edge, DLC-

coated cement carbide

tool with grooves

orthogonal to the

cutting edge, DLC-

coated cemented

carbide tool with

polished tool,

Aluminum A5052

Nano/micro

textured

surfaces on

tool were

created to

improve anti-

adhesive

properties of

tool

Significant

improvement

in anti-

adhesiveness

and lubricity at

tool-chip

interface.


10

Researchers,

Year, and

journal

Machining

type,

parameters

Material of

tool and

work piece

Details of

investigation

Observation/

Finding

El-Hakim et al.,

(2011),

Tribology

International

Turning, Feed

rate=0.05

mm/rev, Depth

of cut=0.15

mm, Cutting

speed=20

m/min, 100

m/min, 200

m/min

Hardened HSS

AISI T15,

Polycrystalline

c-BN, TiN

coated

polycrystalline

c-BN, Mixed

alumina

ceramic,

Tungsten

carbide with

multilayered

TiC/TiCN/Al2

O3 coating and

TiN outer

coating

Wear

mechanism of

cutting tool

materials in

hard turning of

HSS

Wear was

reduced in

coated tools


11

Researchers,

Year, and

journal

Machining

type,

parameters

Material of

tool and

work piece

Details of

investigation

Observation/

Finding

Jianxin et al.,

(2012),

International

Journal of

Refractory

Metals and

Hard Materials

Turning, Feed

rate=0.1

mm/rev, Depth

of cut=0.5 mm,

Cutting

speed=20- 300

m/min

WC/ Co

cemented

carbide, carbon

steel (C-40),

Dry machining,

solid lubricant

Performance of

carbide tools

with textured

rake face filled

with solid

lubricants in

dry cutting

processes

Cutting

performance

was improved

Jianxin et al.,

(2012),

Materials and

Design

Turning,

Sliding speed=3

mm/s, 6 mm/s,

9 mm/s,

Applied

load=20 N, 40

N, 60 N

Cemented

carbide, Ti-6Al-

4V alloy ball,

solid lubricant

Effect of

Surface

texturing on

friction

properties of

cemented

carbide using

Taguchi method

Friction

coefficient of

cemented

carbide is

reduced


12

Researchers,

Year, and

journal

Machining

type,

parameters

Material of

tool and

work piece

Details of

investigation

Observation/

Finding

Enomoto et al.,

(2012), CIRP

Annals-

Manufacturing

Technology

Face milling,

Feed rate=0.2

mm/rev,

Cutting speed=

200 in/min,

Depth of cut= 2

mm, Dry and

wet machining

Cemented

carbide

SEKN42MT,

Carbon Steel

S53C

Nano/micro

textured

surfaces on

highly wear

resistant in

cutting steel

Significant

improvement in

wear resistance

and lubricity

Sugihara et al.,

(2013),

Precision Engg.

Face milling,

Feed rate=0.2

mm/tooth,

Cutting speed=

200 in/min, 800

rpm,

Depth of cut= 2

mm, Dry and

wet machining

Cemented

carbide

SEKN42MT,

Medium carbon

steel

Micro textured

surfaces on tool

to reduce crater

and flank wear

Significant

reduction in

crater and flank

wear


13

Researchers,

Year, and

journal

Machining

type,

parameters

Material of

tool and

work piece

Details of

investigation

Observation/

Finding

Neves et al.,

(2013), Applied

Surface Science

Turning,

Feed rate=0.1

mm/rev,

Cutting speed=

300 m/min, 360

m/min,

Depth of cut=

0.5 mm

Cemented

carbide grade

1005

Microstructural

and wear

analysis of tools

after laser

treatment and

PVD coating

TiAlN PVD

Coated and

laser texture

substrate

hindered notch

wear, Laser

textured tools

have longer life.

Jiang, (2014),

CIRP Annals-

Manufacturing

Engg.

Turning,

Feed rate=0.15

mm/rev,

Cutting speed=

150 m/min,

Depth of cut=

0.50 mm, wet

machining

CBN in soft

titanium nitride

matrix, polished

PCBN,

Hardened steel

4340,

Structural

analysis and

machining

results of a 3-D

nanostructured

coating

designed for

finish turning

ferrous alloys

Superior tool

life and

smoother

surface finish

than other

inserts.


14

Researchers,

Year, and

journal

Machining

type,

parameters

Material of

tool and

work piece

Details of

investigation

Observation/

Finding

Kummel et al.,

(2015), Journal

of Materials

Processing

Technology

Turning,

Feed rate=0.05

mm/rev,

Cutting speed=

100 m/min,

Depth of cut=1

mm, dry

machining

Cemented

carbide, Carbon

steel SAE 1045

Micro texturing

on tool for wear

improvement

and built-up

edge

stabilization

Wear is

decreasing with

dimple texture

and increasing

with channel

micro-texture.

Motivation for the Work

After going through the research papers, we

came on the following conclusions:

• No work has been done by using biomimetic

surfaces.

• The results are not up to the expectations in

all the cases.

• Dry condition machining has not been done.

15

Objective of Project

16

•Tribological (wear by loss of weight and

geometric dimension and temperature rise)

studies of conventional tool inserts employed

in the turning process of carbon steel (C-20) at

various operating parameters (depth of cut, feed

rate, spindle speed) for dry condition.

17

• Tribological (wear by loss of weight and

geometric dimension and temperature rise)

studies of textured (with biological surface

patterns) tool inserts employed in the turning

process of carbon steel (C-20) at various

operating parameters (depth of cut, feed rate,

spindle speed) for dry condition.

• Comparisons of tribological parameters

achieved with conventional and textured

inserts.

Methodology Adopted

• Market survey

• Materials and equipment purchased

• Tungsten carbide tool insert

• Mild steel bar

• Non contact thermometer

18

• Identification of lathe machine and parameters.

Speed Range: 54 - 1200 rpm.

Least count of Feed rate: 0.2 mm/rev

Least count of Depth of cut: 0.04 mm 19

• Selection of tool insert material which is tungsten

carbide insert.

• Number has been given according to the parameters,

that is, spindle speed, feed rate and depth of cut. 20

• Dimensions of tool inserts and workpieces has

been noted.

• Length= 15.148 mm (approx.) and width= 6 mm (approx.) 21

• Weight of tool inserts both textured and

conventional has been noted before and after

the experiment. 22

Laser Texturing of Tungsten

Carbide tool insert S.

No. LASER Parameters Values

1. Crystal used for LASER

Nd:YAG

(Neodymium: Yttrium-

Aluminium-Garnet)

2. Laser Power (W) 20

3. Wavelength (nm) 1064

4. Pulse Frequency (kHz) 2

5. Distance between two grooves (mm) 0.2

6. Scanning speed (mm/s) 5

23

24

• Turning operation has been performed using all

the tool inserts and workpieces at various

parameters..

25

• Temperature had been measured for tool inserts

before and after performing turning operation.

26

Results

27

0

0.5

1

1.5

2

2.5

3

3.5

4

315 500 775

Tem

per

atu

re R

ise

(oC

)

Spindle Speed (rpm)

Variation of temperature of conventional and

textured tool inserts at different spindle speed,

0.12 mm depth of cut and 0.4 mm/rev feed rate

Conventional

Texture

28

0

1

2

3

4

5

6

7

315 500 775

Tem

per

atu

re R

ise

(oC

)

Spindle speed (rpm)




Conventional

Textured

29

0

1

2

3

4

5

6

7

8

9

315 500 775

Tem

per

atu

re R

ise

(oC

)

Spindle Speed (rpm)


textured tool inserts at spindle speed, 0.16 mm

depth of cut and 0.4 mm/rev feed rate

Textured

Conventional

30

0

1

2

3

4

5

6

315 500 775

Tem

per

atu

re R

ise

(oC

)

Spindle Speed (rpm)




Conventional

Textured

31

0

0.5

1

1.5

2

2.5

3

3.5

4

315 500 775

Tem

per

atu

re R

ise

(oC

)

Spindle Speed (rpm)




Conventional

Textured

32

0

1

2

3

4

5

6

315 500 775

Tem

per

atu

re R

ise

(oC

)

Spindle Speed (rpm)




Conventional

Textured

33

• Confocal microscopic image of conventional tool insert at

rpm=315, Depth of cut=0.12 mm, Feed Rate=0.4 mm/rev

34

• Confocal microscopic image of textured tool insert at rpm=315,

Depth of cut=0.12 mm, Feed Rate=0.4 mm/rev

35



36



37



38



39



40



41



42



43



44



45

46

0

1

2

3

4

5

6

7

8

0.4 0.8 1.2 1.6

Wea

r (1

0-4

gm

)

Feed Rate (mm/rev)

Wear Behaviour of conventional tool inserts at

various rpm, feed rate and at 0.12 mm depth of cut

315 rpm

500 rpm

775 rpm

47

-3

-2

-1

0

1

2

3

4

5

0.4 0.8 1.2 1.6 Wea

r (1

0-4

gm

)

Feed Rate (mm/rev)

Wear Behaviour of conventional tool inserts at various

rpm, feed rate and at 0.16 mm depth of cut

315 rpm

500 rpm

775 rpm

48

-3

-2

-1

0

1

2

3

4

5

6

7

0.4 0.8 1.2 1.6

Wea

r (

10

-4 g

m)

Feed Rate (mm/rev)

Wear Behaviour conventional tool inserts at various


315 rpm

500 rpm

775 rpm

49

-25

-20

-15

-10

-5

0

0.4 0.8 1.2 1.6

Wea

r (1

0-4

gm

)

Feed Rate (mm/rev)

Wear Behaviour of textured tool inserts at various


315 rpm

500 rpm

775 rpm

50

-20

-18

-16

-14

-12

-10

-8

-6

-4

-2

0

0.4 0.8 1.2 1.6

Wea

r (1

0-4

gm

)

Feed Rate (mm/rev)

Wear Behaviour of textured tool inserts at various


315 rpm

500 rpm

775 rpm

51

-30

-25

-20

-15

-10

-5

0

0.4 0.8 1.2 1.6

Wea

r (

10

-4 g

m)

Feed Rate (mm/rev)

Wear Behaviour conventional tool inserts at various


315 rpm

500 rpm

775 rpm

Conclusions Drawn

• Temperature rise is in increasing order when the

spindle speed, feed rate and depth of cut is increased

for both textured and conventional tool insert. The rise

in temperature of textured tool insert is less in

comparison to conventional tool insert.

• Weights of conventional tool inserts have decreased

after the turning operation. Whereas the weight of

textured tool inserts has increased because the chips of

workpiece and tool insert articles gets trapped inside

the texture.

52

Conclusion Continues…..

• Wear of conventional and textured tool inserts

changes with change in parameters like spindle

speed, feed rate and depth of cut. Wear is more

for conventional tool inserts in comparison to

textured tool inserts.

53

Scope for Future Work

In future different materials (tool) with different

shapes of textures can be studied to improve the

tribological behaviour of at tool workpiece

interface. Even different workpiece material can

be used to see the tribological effect on the

quality of the workpiece.

54

Gantt Chart S.

No. Activity

Aug.-

2015

Sept.-

2015

Oct.-

2015

Nov.-

2015

Dec.-

2015

Jan.-

2016

Feb.-

2016

Mar.-

2016

April-

2016

1. Literature review

2. Identification and

purchase of tool inserts

and work piece

3. Laser surface texturing on

tool inserts

4. Conducting experiments

on lathe machine

5. Report writing and

presentation of project

6. Conducting experiments

7. Final report writing and

presentation of project

Work to do

Work in progress

Work done

55

References

1. T. Sugihara, T. Enomoto, Development of cutting tool with

nano/ micro- textured surface- improvement of anti-adhesive

effect by considering the texture patterns, Precision

Engineering, Vol 33, 2009, PP. 425-429.

2. M. A. El Hakim, M. D. Abad, M. M. Abdelhammed, M. A.

Shalaby, S. C. Veldhuis, Wear behavior of some cutting tool

materials in hard turning of HSS, Tribology International, Vol

44, 2011, PP. 1174-1181.

3. D. Jianxin, Wuze, L. Yunsong, Q. Ting, C. Jie, Performance of

Carbide tools with Textured rake face filled with solid

lubricants in Dry cutting processes, Refractory & Hard

Materials, Vol 30, 2012, PP. 164-172.

56

4. N. Sugita, K. Ishii, J, Sui, M. Terashima, Multi-grooved

cutting tool to reduce cutting force and temperature during

bone machining, Manufacturing Technology, Vol 63, 2014,

PP. 101-104.

5. T. Cousseau, B. Graca, A. Campos, J. Seabra, Friction

torque in grease lubricated thrust ball bearings, Tribology

International, Vol 44, 2011, PP. 523-531.

6. T. Enomoto, T. Sugihara, S. Yukinaga, K. Hirose, U. Satake,

Highly wear resistant cutting tools with textured surfaces in

steel cutting, Manufacturing Technology, Vol 61, 2012, PP.

571-574.

7. Neves, A. Diniz, M.S.F Lima, Microstructural analysis and

wear behaviour of the cemented carbide tools after laser

surface treatment and PVD coating, Applied Surface

Science, Vol 282, 2013, PP. 680-688. 57

8. K. Bouacha, M. A. Yallese, S. Khamel, S. Belhadi, Analysis

and optimization of hard turning operation using cubic boron

nitride tool, International Journal of Refractory Metals and

Hard Materials, Vol 45, 2014, PP. 160-178.

9. H. Y. Valera, S. N. Bhavsar, Experimental investigation of

surface roughness and power consumption in turning

operation of EN 31 alloy steel, 2nd International Conference

on Innovations in Automation and Mechatronics

Engineering, ICIAME 2014, Vol 14, 2014, PP. 528-534.

10. W. Grzesik, Influence of tool wear on surface roughness in

hard turning using differently shaped ceramic tools, wear,

Vol 265, 2008, PP. 327-335.

58

Thank You for your kind

Attention

59

Documents

Tribological Studies of Laser Textured Tool Inserts in ... Sample ppt.pdf · the area. However here relevant 10 papers have ... 380 in/min, 1500 rpm Depth of cut= 3 mm, Dry and wet