Optimization of Cutting Parameter by using Cryogenically Treated and Coated Tool Inserts-Review

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International Journal on Mechanical Engineering and Robotics (IJMER)

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ISSN (Print) : 2321-5747, Volume-3, Issue-1,2015 15

Optimization of Cutting Parameter by using Cryogenically Treated and Coated Tool Inserts-Review

1Nagraj Patil, ²ShriShail Kakkeri

1Department of Mechanical Engineering, School of Engineering and Technology Jain University Bangalore

2Mechanical Engineering Dept, SVCE Bangalore Email: ¹[email protected], ²[email protected]

Abstract— In this Review paper an attempt is made to review the literature on optimizing the machining parameters in turning processes by using cryogenic treated and coated tool inserts. In machining operations, the extents of significant influence of the process parameters like speed, feed, and depth of cut are different for different responses. Therefore, optimization of surface roughness, cutting force, Material removal rate, Tool life is an important objective problem, Taguchi method, the signal-to- noise ratio and the analysis of variance (ANOVA) are employed to study the performance characteristics in turning operations. The objective of this study is on improvement in the tool life of Cutting tool inserts by using coated and cryogenic treated insert on its various parameters.

Keywords: Cryogenic treatment, cutting tool insert, Tool life, Taguchi Methods, coating

I. INTRODUCTION

Metal cutting process forms the basis of the engineering industry and is involved either directly or indirectly in the manufacture of nearly every product of our modern civilization. The cutting tool is most one of the important elements in realizing the full potential out of any metal cutting operation. Over the years of demands, of economic competition have motivated a lot of research in the field of metal cutting leading to the evolution of new[1] tool materials of remarkable performance and vast potential, for an increase in productivity. Changes in work piece materials, manufacturing method and even the government regulations catalyze parallel advances in metal cutting tooling technology. Cryogenic treatment also known as cold or sub zero treatment process, is a very old process and is widely used for high precision parts. The use of more cold to strengthen metals has been used since long time ago for centuries.[1] For Example, Swiss watch makers use to store the delicate components of their time pieces for several years in mountain caves to stabilize them in order to obtain maximum performance(life) and precision. In general, unlike surface treatments, the cryogenic treatment influence or increases the core

properties of the materials. And the coated tool will effect increase in performance of the cutting tool, [2]

Wear resistant coating on cutting tools is the most significant development in cutting tool technology. Hard coatings like TiC, TiN, Al2O3, AlN etc have established their effectiveness in high performance machining of ferrous materials. Coatings are diffusion barriers; they prevent the interaction between chip formed during the machining and the cutting material itself. All these compounds have low solubility in iron and they enable inserts to cut at much higher rate [2].Figure.1 shows the multilayer coating on the tool inserts.[3]

Fig.1 Structure of a multilayer coated carbideinsert[3]

II. TOOL MATERIAL USED

1. Carbon steel 2. High speed steels 3. Cast Cobalt alloys

4. Carbides (Tungsten carbide and titanium carbide) 5. Carbide tool with CVD & PVD.

6. Silicon Nitride 7. Cubic Boron Nitride 8. Diamond [4]

III. FACTORS AFFECTING THE PROCESS PARAMETERS

Whenever two machined surfaces come in contact with one another surface the quality of the Mating parts plays

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an important role in the performance and the wear of the mating, parts.[4] The height, shape, arrangement and direction of these surface irregularities on the work piece depend upon a number of factors such as: A) The machining variables which include a) Cutting speed b) Feed and c) Depth of cut. B) The tool geometry Some geometric factors which affect achieved Surface finish includes: [4]

IV.CRYOGENIC TREATMENT

Cryo-treatment (CT) is a supplementary process to conventional heat treatment, that involves deep freezing of materials at cryogenic temperatures (-190 °C) to enhance the mechanical and physical properties. The execution of CT on cutting tool materials increases wear resistance, hardness, dimensional stability, but at the same time, reduces tool consumption and down time for the machine tool set up, thus leading to cost reductions.

The dry cryogenic process is precision controlled and the materials to be treated are not directly exposed to any cryogenic liquids. Overall, all the treated materials retain their size and shape. Cryogenically treated materials with some occasional heat treatment generally improve hardness, toughness, stability, corrosion resistance and reduced friction, cryogenic treatment has been successfully applied to die and HSS ferrous [4].

V. LITERATURE REVIEW

M. Sokovic et al [6] have investigated the results of cutting characteristics of the modern sintered ceramic tool inserts coated with PVD and CVD coatings. It was demonstrated, based on the technological cutting tests that puting down onto the ceramic tool inserts the thin wear resistant coatings increases their abrasion wear resistance which has a direct effect on the tool life.

Based on the roughness parameter Ra of the machined cast iron surface after the cutting tests, it has been observer that improvement was revealed of the machined material properties, cut with coated ceramic inserts, compared to material machined with the uncoated inserts ones.

Sagnesh Gaikwad et al [7] They investigated the inserts at various combination of cutting speed, feed ,and depth of cut, for end milling of low carbon steel (EN 8). In the present study the comparison has been made data for experimental study and software study comparing the data for variation of tool wear and surface roughness. The objective of this work is to apply statistical analysis to predict the output variables and establish relationship between the controllable factors (in this study: spindle speed, feed rate and depth of cut) and response factor (surface roughness and tool wear).

Have found that tool wear primarily affected by cutting speed and then secondly affected by feed rate.

Issac Thamban et al [9] has conducted experiment on machining of 6061 Aluminium alloys using diamond coated and uncoated tungsten carbide end mills under the dry conditions is conducted. The alloy has the wide range of applications in the automotive and many other

industries. They studied; the diamond coating of the tools was performed using CVD process. It has been observed that performance of the diamond coated tools has been compared with that of an uncoated tool and the results are presented and analyzed in this work.

D. Pinheiro et al [10] they studied the cutting of wood- based products that the wear of the tungsten carbide cutting tools are always very severe in the first cutting metres. The sharpness that is needed to guarantee a better cutting surface quality induces the weaken cutting tool edge. Until now many studies have been made to search the best coating tool for the carbide inserts.

However, due to the high abrasive wear, coatings with good adhesion and hardness properties mostly, during the first cutting steps, do not lead to a benefit in the cutting tool life. all cases it is verified some intense, presence of fractures that lead to a high delamination, of some coatings that could be attributed to the highest film residual stresses presented in the edge not much can be done to avoid this fact. Nevertheless, it is necessary to understand how the sharpened edge evolutes during the cutting of wood-based products, what are the differences between the worn edge of the uncoated and coated cutting tools. In this work, it was measured the cutting tool edge evolution with a perfilometer, during the cutting of OSB . Two different cutting angles were also compared maintaining the same cutting conditions and geometry of the insert. it has been observe red that Good wear resistant multilayer coatings, with 11 layers, were deposited and tested in cutting.

Gabriela Strnad et al [11] have analysed the recent developments in the field of PVD coating for the manufacturing tools. A review of monoblock, multilayer nanocomposite, DLC and oxinitride coatings is discussed and have found that ,with the emphasis on coatings which enables the manufacturers to implement high productivity, processes such as high speed cutting and dry speed machining.

Lakhwinder Pal Singh, et al [12] et al has conducted experiment on effects of cryogenic treatment on the cutting tool durability High-speed steel (HSS) tools are the most commonly used tools in medium and small scale industry. Cryogenic treatment can be used to increase the tool life. Studies on cryogenically treated cryogenically treated cutting tools show micro structural changes in the material that can influence the life of the tools significantly. This research paper primarily reports performance of cryogenically treated HSS tools as compared to untreated HSS tools. The results show that Cyrogenic treted HSS tools exhibit better performance based on tool wear. The microstructure it has been that found more refined and uniformly distributed after cryogenic treatment of High speed Tool (HSS) tool.

Taguchi L₂₅ orthogonal array was considered for conducting the experimentation and ANOVA used for statistical data analysis. Their Three parameters such as cutting speed, feed rate, and depth of cut at different levels were considered in this research study. ANOVA results shows that the cutting speed is the most

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significant parameter followed by feed rate in both the cases

N. R. Dhar, et al [8] has conducted experiment on cutting temperature, surface roughness, tool wear, and dimensional deviation in cryogenic machining The present work shows the experimental investigation in the role of cryogenic cooling by liquid nitrogen jet on tool wear, cutting temperature, dimensional deviation and surface finish in turning of AISI 1060 steel at industrial speed-feed combination by coated carbide insert. The results of the present work indicate substantial benefit of cryogenic cooling on tool life, surface finish and dimensional deviation. This may be attributed to mainly reduction in cutting zone temperature and favorable change in the chip tool contact. Further it was evident that machining with soluble oil cooling failed to provide any significant improvement in tool life rather surface finish deteriorated.

Mr. Sandip B.Chaudhari et al. [16] founds improvement in wear resistance, and hardness by cryo processing is attributed to the combined effect of conversion of the retained austenite to martensite, and precipitation of η-carbides in case of tool steel. The phenomenon is responsible for improvement in the wear resistance in carbide cutting tools is the combined effect of increased number of η phase particles and increase in bounding strength of binders used. Cryogenic treatments processes substantially decrease the wear rate of the AISI M2 HSS compared to the conventional treated ones. However the improvement in wear rate by deep cryogenic treatment, is significantly higher than that achieved by shallow cryogenic treatment.

P T Mativenga [17] Studied the investigation of contact length and chip morphology in high-speed turning. In this Review paper the performance of five different coatings TiN, TiCN, TiAlN and CrTiAlN (PVD)coatings, and an advanced Dymon-IC hydrogenated amorphous carbon based coating (a-C:H) deposited by plasma enhanced chemical vapour deposition (PECVD) is one of the best CVD technique is to investigated in high-speed machining of AISI – 4140 high-strength alloy steel at cutting speeds ranging between 200 and 920 m/min. Modelling of chip contact length is revisited and the results of extensive machining tests supported by use of a high speed camera are reported. The effects of coatings on the chip compression ratio, back flow angle, tool–chip contact length, frictional force, and tool wear are explored. The result brought a new approach contributes towards a fundamental understanding of heat generation and partition in metal cutting using coated tools.

VI. CONCLUSIONS

Cryogenic treatment causes morphological changes in the entire cross-section of the Tool hence the same tool life can be anticipated even after any number of resharpenings. it is better to all type of coated tools as the coatings become futile, even after single resharpening of tool.

Coated carbide tools perform better than uncoated carbide tools as far as cutting forces are concerned. For average magnitudes of forces obtained with uncoated carbide tool were higher than those obtained with coated carbide tools under experimental conditions.

VII REFERENCE

[1] Machado,M.B. da Silva, Metal Machining. Brazil MG, (2003)

[2] Lakhwinder Pal Singh, Jagtar Singh, Parametric Optimization of Turning Operation using Cryogenically Treated and Un-Treated High Speed Steel Tool, Volume 4, Issue 5, May-2013 2013

[3] Cutting Tool Materials, Valery Marinov, Manufacturing Technology

[4]. Paul, S. and Chattopadhyay, A.B., 1995, “A Study of Effects of Cryo-Cooling in Grinding.”

Int. Journal of Mach. Tool and Manu.35 (1), Pp.109-117

[5] Linde Gas “Sub-zero Treatment of Steels Technology/Processes/Equipment” special edition.

[6] M. sokovic, j. kopac, l.a. dobrzanski, j. mikula, k.

golombek, d. pakula “cutting characteristics of pvd and cvd - coated ceramic tool insert” , Volume 28, No. 1&2, 2006, pp 3-8

[7] Sagnesh Gaikwad, V.D. Patel, S.B. Patel,

“experimental and statistical analysis of pvd and cvd coated cutting tools based on tool wear in end milling of en 8, Volume 1, Issue 9, May- 2014,pp 748-750.

[8] N.R. Dhar a, S. Paulb, A.B. Chattopadhyay “The influence of cryogenic cooling on tool wear, dimensional accuracy and surface finish in turning AISI 1040 and E4340C steels” Wear 249, 932–942, Received 15 September 2000; received in revised form 23 April 2001; accepted 4 July 2001,2002. 2001 Elsevier Science B.V.

[9] Issac Thamban, Biju Cherian Abraham,Sabu Kurian, “machining characteristics analysis of 6061-t6 aluminium alloy with diamond coated and uncoated tungsten carbide tool, jan 2013, Vol 2, pp 553-557.

[10] D. Pinheiro1, G. Goli, M.T. Vieira, “cutting tools edge evolution of coated and uncoated tungsten carbide inserts”.

[11] Gabriela Strnad, Joseph Buhagiar “ latest developments in pvd coatings for tooling” ,Vol 7,2010

[12] Lakhwinder Pal Singh1, Jagtar Singh, effects of cryogenic treatment on the cutting tool durability, international journal of design and manufacturing

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technology (ijdmt), Volume 3, Issue 1, January- December (2012), pp. 11-23

[13] Cselle, T. and Barimani, A., 1995, “Today's Applications and Future Development of Coating for Drills and Rotating Cutting Tools.” Surface and coat. Technol. Vol. 76-77, pp.712.

[14]. Kanamori, S., 1986, “Investigation of Reactively Sputtered Tin Films for Diffusion Barriers.” Thin Solid Films, Vol.136, pp. 195.

[15]. Novak, S. and Komac, M., 1997, “Wear of Cermet Tools Coated with Physical Vapor Deposited TiN.” Wear, Vol. 205, pp. 160-168.

[16] Mr. Sandip B.Chaudhari, Prof. Sanjay P.

Shekhawat, Mr. Ambeprasad S. Kushwaha

“Advanced Technology of Cryoprocessing for the Enhancement of Tool Material Machining Characteristics: A Review” International Journal of Emerging Technology and Advanced Engineering, ISSN 2250-2459, Volume 2, Issue 4, April 2012.

[17] speed turning using coated tools School of Mechanical, Aerospace, and Civil Engineering, University of Manchester, Proc. IMechE Vol.

220,11 April 2011

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