The  objective  of  this  paper  is  to  analyze  the 

influence   of   various   turning   process   parameters   such   as cutting  speed,  feed  rate  and  depth  of  cut  on  the  Feed  force, Tangential   force   &   Surface   roughness   while   machining hardened  EN

-353  steel  with  uncoated  ceramic  insert.  The 

effect  of  the  selected  process  parameters  on  the  Feed  force (FX),  Tangential  force  (FY)  and  Surface  roughness  (Ra)  have been  accomplished  using  Taguchi’s  design  of  experiments approach.   The   results   indicate   that   the   selected   process 

parameters  significantly  affect  the  mean  &  variance  of  Feed force,  Tangential  force  and  Surface  roughness.  The  percent contributions  of  parameters  in  the  ANOVA  table  for  Feed force   (FX)   for   the   depth   of   cut   (87.99%)   has   a   major contribution  than  that  of  feed  rate      (2.82  %)  and  the  cutting speed   (4.45%).   Tangential   force   (FY),   the   depth   of   cut (81.56%)  has  a  majo

r  contribution  than  that  of  cutting  speed 

(3.8%) and feed rate (9.87%). Similarly the Surface roughness (Ra), has depth of cut (59.59%) has a major contribution than that  of  cutting  speed  (23.67%)  and  feed  rate  (4.64%).  In  all these   cases   the   interactions are   not   having   any   major contributions

Dadapeer, B.

Umesh, C.K.

ePrints@Bangalore University

 International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 4, April 2014) 227  Analysis of Forces & Surface Roughness on Hardened Steel With Uncoated Ceramic Insert Using Taguchi Technique. Dadapeer.B1, Dr. C. K.Umesh2 1Associate professor, Department of Mechanical Engineering, AMC Engineering College, Bengaluru, Karnataka, India 2 Associate professor, Department of Mechanical Engineering, UVCE, Bengaluru, Karnataka, India Abstract— The objective of this paper is to analyze the influence of various turning process parameters such as cutting speed, feed rate and depth of cut on the Feed force, Tangential force & Surface roughness while machining hardened EN-353 steel with uncoated ceramic insert. The effect of the selected process parameters on the Feed force (FX), Tangential force (FY) and Surface roughness (Ra) have been accomplished using Taguchi’s design of experiments approach. The results indicate that the selected process parameters significantly affect the mean & variance of Feed force, Tangential force and Surface roughness. The percent contributions of parameters in the ANOVA table for Feed force (FX) for the depth of cut (87.99%) has a major contribution than that of feed rate   (2.82 %) and the cutting speed (4.45%). Tangential force (FY), the depth of cut (81.56%) has a major contribution than that of cutting speed (3.8%) and feed rate (9.87%). Similarly the Surface roughness (Ra), has depth of cut (59.59%) has a major contribution than that of cutting speed (23.67%) and feed rate (4.64%). In all these cases the interactions are not having any major contributions.  Keywords—Cutting force, Feed force, Surface roughness, uncoated Ceramic tool and ANOVA.  I. INTRODUCTION The metal cutting industries in developing countries continue to suffer from a major drawback of not running the machine tools at their operating conditions. The operating conditions continue to the chosen solely on the basis of the handbook values and or work experience. The literature survey has revealed, a little research has been conducted to obtain the machining characteristics of cutting parameters- cutting speed, feed rate, and depth of cut  Hari singh and Pradeep Kumar [1] constructed an Ishikawa cause-effect diagram in order to identify the process parameters that may affect the machining characteristics of turned parts such as cutting tool parameters- Tool geometry and Tool material; workpiece related parameters – metallographic hardness etc., cutting parameters- cutting speed, feed rate and depth of cut, dry cutting and wet cutting. Thamizhmanii S. et al. [2] found that the surface roughness from various tests shows a decrease in values at higher cutting speeds and feed rates.  The cutting tool has produced micro chipping and has not affected the surface finish. Yoichi Matsumoto and Da-Chun Hsu [3] have performed the work piece temperature rise study during the cutting of AISI 4340 steel, that temperature rises in work piece were measured during the cutting of various hardness of steel by a ceramic tool. Thermocouples were embedded in a specially designed work piece for the temperature measurement. The temperature increase in the work piece is quite low when a ceramic tool is used to cut steels of various hardness. The penetration of heat becomes deeper as the cutting speed slows down. P.Munoz – Escalona, Z. Cassier et.al. [4] have studied the influence of the critical cutting speed on the surface finish of turned steel. Variables such as feed rate and the tool nose radius and cutting speed can provide a control on the quality and the surface finish in a given machining process. Singh and Kumar [5] studied on optimization of feed force through setting of optimal value of process parameters namely cutting speed, feed rate and depth of cut in turning of EN-24 steel with TiC coated Tungsten carbide inserts. The authors used Taguchi’s parameters design and concluded that the effect of depth of cut and feed variations of feed force affected more as compared to speed. Sahoo et. al. [6] studied for optimization of machining parameters combinations emphasizing on fractal characterstics of surface profile generated in CNC turning operation. The authors used L27 Taguchi orthogonal array design with machining parameters: cutting speed, feed rate and depth of cut on three different workpiece materials namely Aluminium, Mild steel and Brass. It was concluded that feed rate was more significant in influencing surface finish in all three materials. S. Lo Casto. [7] used wear rates and wear mechanisms of alumina based tool cutting steels at a low cutting speed. Three ceramic insert materials, Zirconia-toughened (Al2O3 -7 vol% ZrO2), mixed based alumina (Al2O3 – TiN – TiC – ZrO2) and alumina reinforced with SiC whickers (Al2O3 - SiCw), were used to cut AISI 1040 steel at 3.9m/s. in addition, a traditional grade P10 inserts (WC-TiC - Co) was rested. The worn zone was observed with scanning electron microscopy techniques.    International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 4, April 2014) 228  A. Bellosi et. al. [8] observed that the demand for TiC-based cermet tool inserts continues to grow and is now second to the WC-Co. this is due to excellent wear resistance and chemical stability at high temperatures. TiN nanopowder mixed with different metal carbides and binders are employed to produce TiC based cermets with TiN nanopowder addition. The binder forms a matrix where ceramic particles are dispersed, provided by ceramic particles, are combined toughness and thermal shock provided by the binder. G. Brandt et al [9] used crater wear of alumina based ceramic cutting tools when machining steel is predominantly dependent upon superficial plastic deformation. Such tool surface deformation may be greatly affected by chemical reactions with work piece materials. Crater surfaces of worn alumina based ceramic tools are coromant grade CC 620 (a pure ceramic, containing Al2O3 and ZrO2) have been analyzed by electron microprobe and cathodoluminescence after turning steel SS 2541 (similar to AISI 4337). It has been found that the deformed surface layer had increased concentrations of iron and magnesium. Both these elements were probably present as spinal phases FeO.Al2O3 and MgO.nAl2O3 in solid solutions. Motorcu and Sahin [10] machined the hardened AISI 1040 steel with triangular and square tools in different machining conditions and modeled the surface parameters on surface roughness. They classified the effects of machining and cutting speed respectively. They stated that the lowest surface roughness is produced with square tools. S.Mittal et.al. [11] have recently been proven that it is feasible to use hard turning in selected conditions to surface finish, hardened to 64 HRC, to surface finish of 2 micro inches, thus making it possible to eliminate the need for separate grinding and abrasive-based super finish in a broad range of production activities involving hardened workpieces.  II. EXPERIMENTAL DETAILS The heat treated EN-353 steel is selected as the work material for turning operation. The following process parameters were selected for the present work: cutting speed-(A), feed rate-(B), and depth of cut-(C), Tool material- uncoated ceramic insert (Kennametal Widia)   make. Insert geometry- MTJNR2020M12. Tool holder- MTJNR2020K16. Cutting conditions-Dry  Tool overhang-20 mm    Selection of an orthogonal array (OA): In selecting an appropriate OA, the prerequisites are: i) Selection of process parameters and interactions to be evaluated ii) Selection of number of levels for the selected parameters. The non-linear behavior of the process parameters if exists, can only be revealed if more than two level of the parameters along with their values at three levels are given in Table 1. It was also decided to study the two factor interaction effects on the cutting force [9]. The selected interactions were: i)     Between cutting speed and feed (AxB) ii)    Between feed and depth of cut (BxC) iii)   Between speed and depth of cut (AxC) The three parameters each at three levels and three second – order interactions were selected and the total degree of freedom (DOF) required is 18, since a three level parameter has 2 DOF (number of levels – 1) and  each second order interaction has 4 DOF (product of DOF of interacting parameters). As per Taguchi’s method the total DOF of the selected OA must be greater than or equal to the total DOF required for the experiment. In this paper Taguchi’s method approach is used to analyze the cutting forces, surface roughness and optimum cutting conditions for Feed force (Fx), Tangential force (Fy) and surface roughness (Ra)  by considering the turning process parameters like cutting speed, feed and depth of cut using uncoated ceramic insert while machining EN-353 steel. EN-353 steel rods of 60 mm diameter and 300 mm length were machined on HMT Lathe having power 3.5 KW using uncoated ceramic inserts having the designation MTJNR2020M12. The workpiece is machined as per the process parameters given in Table 1. The Feed force (Fx) & Tangential force (Fy) were measured for each trial using lathe tool dynamometer and the Surface (Ra) is measured using Talysurf. The Analysis of Variance (ANOVA) for raw data and Signal to Noise ratio are calculated for Feed force (Fx), Tangential force (Fy) and Surface roughness (Ra) and are tabulated in Table 3 to Table 8. The Signal – to – Noise ratio for LB characteristics are calculated using:  S/NLB = -10 log (  ∑        )    (1)       International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 4, April 2014) 229  TABLE 1  shows the details of the process parameters: The experiments are conducted as per the process parameters listed in Table 1, using Taguchi Technique L27 cycle. TABLE 2 shows the details of experimental data of Feed force (FX), Tangential force (FY) and Surface roughness (Ra) for L27.  Sl. No FX N FY N Ra µm  S/N-FX S/N-FY S/N-Ra 1 30 50 1.19 -29.54 -33.97 -1.43 2 90 90 1.25 -39.08 -39.08 -1.94 3 120 130 1.36 -41.58 -42.27 -2.67 4 20 80 1.01 -26.02 -38.07 -0.17 5 90 100 1.10 -39.08 -40 -0.82 6 120 160 1.30 -41.58 -44.08 -2.34 7 20 70 1.04 -26.02 -36.90 -0.25 8 110 110 1.25 -40.82 -40.82 -1.93 9 130 210 1.36 -42.27 -46.44 -2.67 10 50 70 1.24 -33.97 -36.90 -1.93 11 100 100 1.36 -40 -40 -2.60 12 130 160 1.5 -42.27 -44.08 -3.52 13 30 90 1.07 -29.54 -39.08 -0.50 14 100 120 1.16 -40 -41.58 -1.21 15 130 180 1.39 -42.27 -45.10 -2.8 16 40 90 1.11 -32.04 -39.08 -0.90 17 130 130 1.35 -42.27 -42.27 -2.60 18 150 230 1.45 -43.52 -47.23 -3.22 19 30 50 1.05 -29.54 -33.97 -0.42 20 90 90 1.15 -39.08 -39.08 -1.21 21 90 150 1.26 -39.08 -43.52 -2.07 22 20 60 0.96 -26.02 -35.56 -0.45 23 90 100 1.08 -39.08 -40 -0.66 24 90 160 1.3 -39.08 -44.08 -2.28 25 30 70 0.90 -29.54 -36.90 -0.91 26 90 110 1.07 -39.08 -40.82 -0.50 27 140 210 1.2 -42.92 -46.44 -1.63 TABLE 3 shows ANOVA results for Feed force (FX). TABLE 4  shows ANOVA results for Signal to Noise ratio (S/N) for Feed force (FX).         Process parameters Parameters Designation Levels L1 L2 L3 Cutting speed (m/min) A 101.78 131.94 171.53 Feed (mm/rev) B 0.125 0.148 0.187 Depth of cut (mm) C 0.05 0.10 0.20 Factor DOF SS MSS Fcal Ftab confidence level P= (SS/SST)* 100 90% 95% 99% A 2 2096.2 1048.1 53.39 3.11 4.46 8.65 4.45% B 2 1340.7 670.37 34.14 3.11 4.46 8.65 2.82% C 2 41385 20692 1054 3.11 4.46 8.65 87.99% AxB 4 125.92 31.48 1.60 2.81 3.84 7.01 0.26% BxC 4 903.70 225.92 11.50 2.81 3.84 7.01 1.92% AxC 4 348.14 87.03 4.43 2.81 3.84 7.01 0.74% Error 8 19.63 2.45     1.82% Total 26 47029      100% Factor D O F SS MSS Fcal Ftab confidence level P= (SS/SST)* 100 90% 95% 99% A 2 33.60 16.80 2.146 3.11 4.46 8.65 3.8% B 2 15.29 7.648 0.977 3.11 4.46 8.65 1.67% C 2 820.49 410.2 52.41 3.11 4.46 8.65 90.02% AxB 4 2.17 0.543 0.069 2.81 3.84 7.01 0.23% BxC 4 17.72 4.431 0.566 2.81 3.84 7.01 1.94% AxC 4 14.32 3.582 0.457 2.81 3.84 7.01 1.56% Error 8 7.82 0.978     0.84% Total 26 911.44      100%  International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 4, April 2014) 230  TABLE 5  shows ANOVA results for Tangential force (FY). TABLE 6 shows ANOVA results for Signal to Noise ratio (S/N) for Tangential force (FY). TABLE 7 shows ANOVA results for Surface roughness (Ra). TABLE 8 shows results for the Signal to Noise ratio (S/N) for Surface roughness (Ra).  III. RESULT AND DISCUSSION From Table 3, the ANOVA from Feed force (FX) for confidence level of 90%, 95% and 99%, it is observed that depth of cut has a significant percent contribution (87.99%) compared to the feed rate (4.45%) and cutting speed (2.82%).The Signal to Noise ratio for Feed force (FX) also exhibits similar trend and these are tabulated in Table 4.  However there is no much major contribution from the interactions (AxB), (BxC), (AxC) and error respectively.   From Table 5 Tangential force (FY) for confidence level of 90%, 95% and 99%, it is observed that the depth of cut has a significant percent contribution (81.56%) compared to feed rate (9.87%) and cutting speed (3.28%). The Signal to Noise ratio for Tangential force (FY) also exhibits similar trend and these are tabulated in Table 6. However there is no much major contribution from the interactions (AxB), (BxC), (AxC) and error respectively.  From the Table 7 the ANOVA for surface roughness (Ra) for confidence level of 90%, 95% and 99%, it is observed that depth of cut has a significant percent contribution (59.59%), compared to cutting speed (23.67%) and feed rate (4.64%). The Signal to Noise ratio for Surface roughness (Ra) also exhibits similar trend and these are tabulated in Table 8. However there is no much significant contribution from the interactions (AxB), (BxC), (AxC) and error respectively. IV. CONCLUSION  The depth of cut is having a significant percent contribution in the Feed force (FX), Tangential force (FY) and Surface Roughness (Ra).  From the ANOVA table for Feed force, Tangential force & Surface Roughness for 90%, 95% and 99% confidence level, there is no change in percent contribution except for the F-tabulated values. As the confidence level increases the F-tabulated values also increases. However there is no much significant contribution from the interactions (AxB), (BxC), (AxC) and error respectively. The S/N ratio for Feed force, Tangential force and Surface roughness for L27 also exhibits similar trends and these are tabulated in Table 4, 6 and 8 respectively. REFERENCES [1] Hari Singh and Pradeep Kumar, ―Quality optimization of turned parts (EN-24 steel) by Taguchi method productivity journal, vol.44, No.1, April – June 2003, pp.43 – 49. [2] Thamizhmanii S. ―Tool Flank Wear Analyses on Martensitic Steel by Turning‖. International Scintific Published monthly by the Wold Academy of Material and Manufacturing Engineering. Vol.32 july 2008, page -41-44.  Factor DOF SS MSS Fcal Ftab confidence level P= (SS/SST)* 100 90% 95% 99% A 2 2140.7 1070 6.57 3.11 4.46 8.65 3.28% B 2 6429.6 3214 19.75 3.11 4.46 8.65 9.87% C 2 53096 26548 163.1 3.11 4.46 8.65 81.56% AxB 4 148.14 37.03 0.22 2.81 3.84 7.01 0.22% BxC 4 2992.5 748.1 4.59 2.81 3.84 7.01 4.59% AxC 4 148.14 37.03 0.22 2.81 3.84 7.01 0.22% Error 8 162.72 20.34     0.25% Total 26 65118      100% Factor D O F SS MSS Fcal Ftab confidence level P= (SS/SST)* 100 90% 95% 99% A 2 15.25 7.62 19.414 3.11 4.46 8.65 4.29% B 2 27.70 13.85 35.468 3.11 4.46 8.65 7.80% C 2 295.3 147.6 375.72 3.11 4.46 8.65 83.19% AxB 4 295.3 1.54 3.93 2.81 3.84 7.01 1.74% BxC 4 6.17 2.51 6.39 2.81 3.84 7.01 2.83% AxC 4 10.05 0.89 2.28 2.81 3.84 7.01 1.01% Error 8 3.14 0.39     0.88% Total 26 354.9      100% Factor DOF SS MSS Fcal Ftab confidence level P= (SS/SST)* 100 90% 95% 99% A 2 0.146 0.07 4.537 3.11 4.46 8.65 23.67% B 2 0.057 0.02 1.295 3.11 4.46 8.65 4.64% C 2 0.367 0.18 11.41 3.11 4.46 8.65 59.59% AxB 4 0.020 0.05 3.149 2.81 3.84 7.01 3.29% BxC 4 0.209 0.05 3.242 2.81 3.84 7.01 3.38% AxC 4 0.017 0.14 0.274 2.81 3.84 7.01 2.86% Error 8 0.012 0.01     2.56% Total 26 0.617      100% Factor DOF SS MSS Fcal Ftab confidence level P= (SS/SST)* 100 90 % 95% 99% A 2 8.05 4.02 276.4 3.11 4.46 8.65 23.6 % B 2 3.17 1.58 109.0 3.11 4.46 8.65 9.34% C 2 19.9 9.98 685.4 3.11 4.46 8.65 58.61% AxB 4 1.18 0.29 20.36 2.81 3.84 7.01 3.48% BxC 4 1.47 0.36 25.29  2.81 3.84 7.01 4.32% AxC 4 0.09 0.02 1.613 2.81 3.84 7.01 0.28% Error 8 0.11 0.01     0.35% Total 26 34.0      100%  International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 4, April 2014) 231  [3] Yoichi Matsumoto and Da-Chun Hsu ―Performed the workpiece temperature rise during cutting of AISI 4340 Steel‖. Wear, 116(1987)309-317. [4] P.Munoz – Escalona, Z. Cassier –―The influence of the critical cutting speed on the surface finish of turned steel‖. Wear 220(1998)21-33 [5] Singh.H. and Kumar. P. ―Optimizing feed force for turned parts through the Taguchi Technique‖, Sadhana (2006), vol.31, No.6, pp. 671 – 681. [6] Sahoo P, Barman T.K. and Routasa B.C, ―Taguchi based practical dimension modeling and optimization in CNC turning‖, Advance in Production Engineering and Management (20008), vol. 3, No.4, pp. 205 – 217. [7] S. Lo Casto-―Wear rates and Wear meachanism of Alumina-base tools cutting steel at a low cutting speed‖. Wear 208(1997)62-67.                                      [8] A.Bellosi, R.Calzavarini, Faga M.G.Monteverde, ―Characterization and application of Titanium Carbonitide-based cutting tools‖. J.Mater Process Technol.143(2003)527-532. [9] G. Brandt and M.Mikus, ―An electron microprobe and cathodoluminescence study of chemical reactions between tool and workpiece when turning steel with alumina-based ceramics‖, Wear 115(1987)243-263. [10] Motorcu AR., Sahin Y.Modeling of surface roughness in the machinability of hardened low carbon AISI 1040 steel with different geometry coated carbide insert. In: Proceeding of the 4th International advanced technologies symposium 28 – 30 september p. 860 – 865. [11] S.Mittal, C.R. Liu, ―A Method of Modeling Residual Stresses in Superfinish Hard Turning‖. Wear 218(1998)21-33.   

Analysis of Forces and Surface Roughness on Hardened steel with uncoated ceramic insert using Taguchi Technique

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Analysis of Forces and Surface Roughness on Hardened steel with uncoated ceramic insert using Taguchi Technique

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