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CHAPTER 5
5.1 INTRODUCTION
Figure 5.1 (a-c) illustrates the contour maps in the feature plane for
the cutting force at different level of depths of cut. These response contours
can help in the prediction of the cutting force at any zone of the experimental
domain.
171
Figure 5.2 (a-c) illustrates the 3D response surface plots for the
cutting force. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is clear from these figures that the magnitude of the cutting
force component is high at lower level of cutting speed and higher level of
feed rate.
(a) 3D response surface plots for the cutting force at 0.75 mm depth of cut
(b) 3D response surface plots for the cutting force at 33 m/min cutting speed
173
(c) 3D response surface plots for the cutting force at 0.102 mm/rev feed rate
Figure 5.2 (a-c) 3D Response Surface Plots for the Cutting Force using
PVD coated carbide Insert
The cutting force is reduced when the level of depth of cut and feed
rate is reduced. It is found that the cutting force (Fz) varies between the range
of 340-585 N in machining nimonic C-263 alloy under different level of
machining parameters using PVD coated carbide insert. The influence of the
machining parameters on the cutting force is illustrated in Figures 5.3-
5.5.From Figure 5.3, it is observed that the magnitude of the cutting force
tends to increase when the feed rate increases, for all levels of cutting speed.
Further it is observed that, the maximum cutting force of 486 N is generated
at a higher level of feed rate and a middle level cutting speed.
550
500
450
400
350 Cutting speed = 22 m/min
300 Cutting speed = 33 m/min
Cutting speed = 54 m/min
250
0.05 0.102 0.143
Feed rate (mm/rev)
550
500
450
400
350 depth of cut = 0.50 mm
depth of cut = 0.75 mm
300 depth of cut = 1 mm
250
22 33 54
Cutting speed (m/min)
Figure 5.5 shows that the magnitude of the cutting force tends to
increase, when the feed rate and depth of cut increases. The maximum cutting
force of 499 N is observed at a higher level of depth of cut and feed rate. At a
higher feed rate the cutting force increases as the flank wear increases, which
are evidently seen in Figure 5.6. The increase in the flank wear at a higher
feed rate creates the damage on the cutting edge, producing the abrasion
between the tool edge and work piece surface, thus the generation of the
cutting force is also high.
175
550
500
450
400
350 feed rate = 0.051 mm/rev
feed rate = 0.102 mm/rev
300 feed rate = 0.143 mm/rev
250
0.5 0.75 1
Depth of cut (mm)
500
0.2
450
0.1
400 Cutting force
flank wear
350 0
0.051 0.102 0.143
Feed rate (mm/rev)
Figure 5.6 Effect of Feed Rate on Cutting Force and Flank Wear at
cutting speed of 33 m/min and 0.75 mm depth of cut
Figure 5.7 (a-c) illustrates the contour maps in feature plane for the
temperature at tool tip at different depths of cut. These response contours can
help in the prediction of the temperature rise at tool tip at any zone of the
experimental domain.
176
Figure 5.7 (a-c) Temperature at tool tip contours in velocity- feed plane
at different depths of cut for PVD Coated Carbide Insert
177
Figure 5.8 (a-c) illustrates the 3D response surface plots for the
temperature rise at tool tip. These surface plots are drawn, using the
developed RSM model by varying the two different parameters and keeping
the third parameter at the middle level. It is clear from these figures that the
magnitude of the temperature rise at tool tip is high at high cutting speed and
at a high feed rate.
(a) 3D response surface plots for the temperature at tool tip at 0.75 mm
depth of cut
(b) 3D response surface plots for the temperature at tool tip at 33 m/min
cutting speed
178
(c) 3D response surface plots for the temperature at tool tip at 0.102
mm/rev feed rate
The temperature at tool tip is reduced when the level of depth of cut
and feed rate is reduced. It is found that the temperature at tool tip varies
between the range of 300-600°C in machining nimonic C-263 alloy under
different levels of machining parameters using the PVD coated carbide insert.
Further the effects of machining parameters on temperature rise at the tool tip
during machining nimonic C-263 alloy are shown in the Figures 5.9 - 5.11.
From Figure 5.9, it is observed that the magnitude of the temperature rise at
tool tip tends to increase when the feed rate and cutting speed increases and
also, it is observed that the maximum temperature of 583 C is generated at a
higher level feed rate and a high level cutting speed. The results indicated that
the increase of feed rate increases the temperature at the tool tip. At increasing
cutting speed and feed rate, the concentration of higher temperature very close
to the cutting edge causes the notching and flank wear.
179
600
550
500
450
400
350 Cutting speed = 22 m/min
Cutting speed = 33 m/min
300 Cutting speed = 54 m/min
250
0.05 0.102 0.143
Feed rate (mm/rev)
600
550
500
450
400
depth of cut = 0.50 mm
350 depth of cut = 0.75 mm
300 depth of cut = 1 mm
250
22 33 54
Cutting speed (m/min)
Figure 5.10 Effect of Cutting Speed on Temperature at Tool Tip at
Different Depths of Cut
600
550
500
450
400
350 feed rate = 0.051 mm/rev
feed rate = 0.102 mm/rev
300 feed rate = 0.143 mm/rev
250
0.5 0.75 1
Depth of cut (mm)
Figure 5.12 (a-c) illustrates the contour maps in feature plane for
the surface roughness at different depths of cut. These response contours can
help in the prediction of the surface roughness at any zone of the experimental
domain.
181
Figure 5.13 (a-c) illustrates the 3D response surface plots for the
surface roughness. These surface plots are drawn, using the developed RSM
model by varying the two different parameters and keeping the third
parameter at the middle level. It is clear from these figures that the magnitude
of the surface roughness is high at low cutting speed and at a high feed rate.
The surface roughness is reduced when the level of cutting speed is increased.
(a) 3D response surface plots for the surface roughness at 0.75 mm depth of cut
(c) 3D response surface plots for the surface roughness at 0.102 mm/rev
feed rate
Figure 5.13 (a-c) 3D Response Surface Plots for the Surface Roughness
using PVD Coated Carbide Insert
have caused the reduction in the surface roughness when the cutting speed is
increased.
3
2.5
2
1.5
Cutting speed = 22 m/min
1 Cutting speed = 33 m/min
Cutting speed = 54 m/min
0.5
0.05 0.102 0.143
Feed rate ( mm/rev)
3
2.5
2
1.5
depth of cut = 0.50 mm
1 depth of cut = 0.75 mm
depth of cut = 1 mm
0.5
22 33 54
Cutting speed ( m/min)
The significance of the feed rate is higher over cutting speed and depth
of cut. This indicates the rubbing of the worn flank, and the associated change in
the surface roughness. This is clearly shown in Figure 5.16 (a-c), in which the
surface roughness tends to increase, as the flank wear increases at all levels of
the cutting speed. In addition, the low thermal conductivity of the nimonic C-263
alloy contributes to the higher generation of heat at the tool work contact zone.
185
0.4 3.9
0.35 flank wear
3.4
0.3 Surface roughness
0.25 2.9
0.2 2.4
0.15
0.1 1.9
0.05 1.4
0.051 0.102 0.143
Feed rate (mm/rev)
(b) Effect of feed rate on flank wear and surface roughness at cutting
speed of 33 m/min and depth of cut of 0.75 mm
0.4
0.35 3.2
0.3 2.7
0.25
0.2 2.2
0.15 flank wear
1.7
0.1 Surface roughness
0.05 1.2
0.051 0.102 0.143
Feed rate (mm/rev)
(c) Effect of feed rate on flank wear and surface roughness at cutting
speed of 54 m/min and depth of cut of 0.75 mm
Figure 5.16 (a-c) Effect of Feed Rate on Flank Wear and Surface
Roughness at Different all Level of Cutting Speed for PVD
Coated Carbide Insert
186
3
2.5
2
1.5
1
feed rate = 0.051 mm/rev
0.5 feed rate = 0.102 mm/rev
feed rate = 0.143 mm/rev
0
0.5 0.75 1
Depth of cut ( mm)
Figure 5.17 Effect of Depth of Cut on Surface Roughness Different Feed
Rates
Figure 5.19 (a-c) illustrates the contour maps in feature plane for
the flank wear at different depths of cut, which can help in the prediction of
the flank wear at any zone of the experimental domain.
188
Figure 5.20 (a-c) illustrates the 3D response surface plots for the
flank wear. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is clear from these figures that the least flank wear occured at
middle level cutting speed and at low level of feed rate and depth of cut;
however, it increases with increase in feed rate and depth of cut. It is found
that the flank wear varies between the range of 0.19-0.38 mm in machining
nimonic C-263 alloy under different level of machining parameters using the
PVD coated carbide insert.
(a) 3D response surface plots for the flank wear at 0.75 mm depth of cut
(b) 3D response surface plots for the flank wearat 0.102 mm/rev feed rate
190
(c) 3D response surface plots for the flank wear at 33 m/min cutting
speed
Figure 5.20 (a-c) 3D Response Surface Plots for the Flank Wear using
PVD Coated Carbide Insert
The flank wear was high at higher cutting speed and feed rates as
seen from the Figure 5.21. The flank wear is high at high level cutting speed
and depth of cut while the flank wear is low comparatively at middle level of
cutting speed and low level of depth of cut as observed in Figure 5.22.
0.4
0.35
0.3
0.25
Cutting speed = 22 m/min
0.2 Cutting speed = 33 m/min
Cutting speed = 54 m/min
0.15
0.05 0.102 0.143
Feed rate (mm/rev)
0.45
0.4
0.35
0.3
0.25
0.2 depth of cut = 0.50 mm
0.15 depth of cut = 0.75 mm
depth of cut = 1 mm
0.1
22 33 54
Cutting speed (m/min)
0.5
0.4
0.3
Figure 5.23 Effect of Depth of Cut on Flank Wear at Different Feed Rates
Figure 5.24 (a-f) shows the SEM images of the flank wear land of
PVD coated carbide insert (S grade) at different cutting conditions. From the
SEM micrographs Figure 5.24 (a-c), the initiation of wear marks can be seen
at the flank of the insert, which can be attributed to the abrasive action of
micro hard carbide precipitates present in the work material and thus the main
wear mechanism at the lower cutting speed of 22m/min. However, as tool
wear progresses, the contact between tool flank and machined work surface
increases, which leads to increase in wear and also the possibility of low order
edge chipping as seen from Figure 5.24 (c).
The experimental results and RSM modelled values for the cutting
force, temperature at tool tip, surface roughness and flank wear in machining
nimonic C-263 alloy using PVD coated carbide insert is shown in Table 5.1.
From the Table 5.1, a good aggrement is obtained between the actual
experimental results and predicted values based on RSM model, indicating
the effectiveness of prediction of cutting force, temperature at tool tip, surface
roughness and flank wear with 95% confidence levels during the machining
of the nimonic C-263 alloy using PVD coated carbide insert.
The average percentage error for the responses such as the cutting
force, temperature at tool tip, surface roughness and flank wear between the
experimental results and ANN model values were 2.72%, 1.19%, 1.76%, and
4.17% respectively.
195
Table 5.1 Experimental and Model Results for PVD Coated Carbide
Insert
Table 5.2 Percentage Error Between the Experimental, RSM and ANN
with Respect to PVD Coated Carbide Insert
% error % error
Expt Experimental Vs RSM Experimental Vs ANN
No Fz Ra VB Fz Ra VB
(N) C) (µm) (mm) (N C) (µm) (mm)
1 12 1.14 2.22 1.33 4.76 4.33 0.57 4.54
2 5 0.66 0 0.31 0.95 0 0.54 0
3 8 2.89 1.1 0.29 0.42 0.29 0.13 0
4 0.66 3.11 3.84 1.29 7.77 0.25 0.88 3
5 8.70 5 1.85 0.48 0.47 1.92 0.14 1
6 8 3 5 1.36 1.77 0.22 5.18 1
7 1.29 4.36 6 0.64 0.18 0 0.36 6
8 4.10 5.62 0 0 1.25 0.20 2.55 0
9 5.29 4.60 6 1 2.39 0 1.20 0
10 5 7 5 7 3.65 0.26 0 14
11 2 3.92 0 1.1 1.03 0 1.96 0
12 1.46 2.28 4 0.68 1.21 7.35 0.71 4
13 13 0.21 10 0.21 0.39 4.42 2.56 10
14 5 1.42 2.0 2.35 0.48 0 0.47 6.12
15 1.57 2.53 1.88 1.69 0.89 0.18 0.16 5
16 6 7 8 1.46 4 0.18 1.97 4
17 2.35 4 3.70 1 0.98 1.80 3.70 3
18 6.31 9 10 1.39 14.73 0.52 1.67 5.88
19 2 2 8 1.72 3.03 2.58 2.01 5.71
20 1.81 2.81 6 1 2.84 0 2.22 0
21 2.59 5 6 0.19 2.07 0 1.44 0
22 0 4.80 6.66 0 0.23 4.23 0.54 3
23 7.8 6 6.84 1.29 2.06 0.55 2.11 9.58
24 1 0.72 5.26 2.32 1.25 0 4.35 10
25 3.61 1.65 4.10 0.17 10 0.35 0 6
26 2.85 2.12 5.71 1.36 1.19 1.36 0.42 2.85
27 4.10 1.88 3.89 3.10 3.65 1.16 9.90 9
cutting force, temperature at tool tip, surface roughness and flank wear with
ANN model seems to have better prediction potential in machining of
nimonic C-263 alloy using PVD coated carbide insert. However, the ANN
model consumes lesser computational time besides giving higher accuracy
(Ranganathan et 2010). The models designed by ANN and RSM models would
be helpful to predict these responses during the machining of the nimonic C-263
alloy using PVD coated carbide insert.
14
12 Fz
10
Ra VB
8
6
4
2
0
1 2 3 4 5 6 7 8 9 1011 12 13 1415161718 192021 22 2324 252627
Experiment Number
14
12 Fz
Ra VB
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Experiment Number
Table 5.3 Plan of the Confirmation Experiments and Results for PVD
Coated Carbide Insert
1 23 0.05 0.50 381 385 307 315 1.71 1.80 0.22 0.20
2 23 0.05 0.50 381 378 307 320 1.71 165 0.22 0.21
3 23 0.05 0.50 381 375 307 310 1.71 170 0.22 0.20
The Finite Element Model has been carried out to predict the responses such
as the cutting force, temperature at tool tip, effective stress and effective strain
through simulation. The simulated model of the cutting force, temperature at
tool tip is compared with the experimental results.
199
From the Figure 5.26, it can be seen that the predicted values are
closer to the experimental values. Further, from the Figure 5.27, the
percentage error computed between the experimental and FEM predicted
values ranges almost within 6%, which clearly indicates the reasonable
correlation between the FEM model and experiment. Thus the simulated
FEM results can be used effectively for predicting the cutting force while
turning nimonic C-263 alloy.
800
700
600
500
400
300
200 Fz-Experimental value
100 Fz-Predicted thro FEM model
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure 5.26 Comparison of Measured and Simulated Cutting Force
14
12
10
8
6
4
2
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure.5.27 Percentage Error Between Experimental and Predicted
Values for Cutting Force
200
Fz Fz Stress Strain
(N) (°C) (N) (°C) (MPa) (mm/mm)
1 22 0.05 0.50 340 300 398 325 375 3.100
2 22 0.05 0.75 420 320 425 340 405 3.250
3 22 0.05 1 470 340 455 365 435 3.750
4 22 0.102 0.50 400 385 435 370 500 4.050
5 22 0.102 0.75 435 415 455 390 520 4.225
6 22 0.102 1 450 440 465 465 575 4.350
7 22 0.143 0.50 542 465 580 490 620 4.650
8 22 0.143 0.75 560 485 585 510 630 4.750
9 22 0.143 1 585 500 662 540 645 4.925
10 33 0.05 0.50 320 375 365 410 400 3.575
11 33 0.05 0.75 385 420 410 430 425 3.725
12 33 0.05 1 410 435 425 440 480 3.825
13 33 0.102 0.50 425 475 430 510 600 4.700
14 33 0.102 0.75 415 510 425 545 630 4.925
15 33 0.102 1 445 530 460 550 690 5.200
16 33 0.143 0.50 475 545 495 585 700 5.420
17 33 0.143 0.75 510 555 520 570 720 5.350
18 33 0.143 1 475 575 495 610 730 5.575
19 54 0.05 0.50 395 465 410 485 590 4.750
20 54 0.05 0.75 386 490 415 510 610 4.600
21 54 0.05 1 385 510 395 535 650 4.800
22 54 0.102 0.50 420 520 415 545 690 5.100
23 54 0.102 0.75 440 540 445 555 720 5.400
24 54 0.102 1 400 560 391 575 750 5.725
25 54 0.143 0.50 442 565 455 590 785 6.125
26 54 0.143 0.75 420 585 435 620 790 6.250
27 54 0.143 1 438 600 450 610 810 6.550
201
(d) Simulated cutting force at cutting speed of 22m/min, feed rate of 0.143
mm/rev and depth of cut of 1 mm
203
(e) Simulated cutting force at cutting speed of 33m/min, feed rate of 0.102
mm/rev and depth of cut of 1 mm
FEM model and experimentally measured temperature at the tool tip are
compared in Figure 5.29. The percentage error between the experimental and
predicted values through FEM model ranges within 8% percentage as shown
in the Figure 5.30. From the Figures 5.29 and 5.30, it can be seen that the
predicted values are reasonable closer to the experimental values.
800
700
600
500
400
300
200 Temp-Experimental value
Temp-Predicted thro FEM model
100
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
the temperature generation at the tool tip increases with increasing the cutting
speed, feed rate and depth of cut. From the illustrations, the highest cutting
temperature occurred at the end of tool tip to an extent of 610°C at a
combination of cutting speed 54m/min, feed rate 0.143mm/rev and depth of
cut of 1 mm. However with lower cutting conditions a temperature around
370°C near the tool tip is observed. From the Figure 5.31 (a-c), it can be seen
that the highest tool face temperature could be located at the tip of cutting
edge which clearly shows the basic machining characteristic of the low
thermal conductivity Nickel based nimonic C-263 material, which agrees with
the reported results by (Smart et al 1975).
(a) Effective stress distributions at cutting speed of 22 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
(b) Effective stress distributions at cutting speed of 33 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
(c) Effective stress distributions at cutting speed of 54 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
(a) Effective strain distributions at cutting speed of 22 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
(b) Effective strain distributions at cutting speed of 33 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
(c) Effective strain distributions at cutting speed of 54 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
1000
800
600
400
200
Effective stress (MPa)
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
30
25
20
15
10
Effective strain (mm/mm)
5
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
In this research work, an attempt has also been made to monitor the
status of the PVD coated carbide insert by acquiring AE signal while turning
nimonic C-263 alloy at different cutting speed and feed rate, at constant depth
of cut.
known sources of AE, and monitoring the AE signal from the cutting zone
can provide useful information concerning the status of the cutting edges as
well as the process itself. Thus the status of the cutting tool to machining
environment was assessed by integrating suitable AE transducer near cutting
edge and monitoring online the acoustic emission signal emitted from the
cutting zone. The acoustic emission from the cutting process consists of
continuous and transient signals, each corresponding to the different events
like, tool wear, and chipping. While sensing the AE signals, the depth of cut
was kept constant at 0.75mm. Typical FFT of the AE signals generated at
different tool wear conditions and at different cutting conditions are shown in
Figure 5.36 (a-f).
higher feed rate also more. Due to this, the energy of the signal produced is
high as seen from all the Figures. 5.36 (e to f), i.e. the signal is spread in
wider range, than at lower combinations of cutting conditions. As the tool
flank wear increases, an increase in the amplitude of the signal seen. Apart
from the occurrence of low frequency components of 50 kHz as seen from the
lower cutting conditions, the dominant peaks are also seen at frequencies of
75 kHz, 125 kHz, 250 kHz and 350 kHz, possibly due to higher order
stressing of the material at higher cutting speed indicating worn out status of
the tool.
(d) Fast Fourier Transform of Acoustic Emission cutting speed of V-33 m/min,
feed rate of 0.143 mm/rev and depth of cut of 0.75 mm
214
Figure 5.37 (a-c) illustrates the contour maps in feature plane for
the cutting force at different depths of cut, the contour can help in the
prediction of the cutting force at any zone of the experimental domain.
Figure 5.38 (a-c) illustrates the 3D response surface plots for the
cutting force. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is observed from these Figures 5.38 (a-c) that the lowest
cutting force is obtained at a higher level of cutting speed and lower level of
feed rate and depth of cut. It is also found that the cutting force (Fz) varies
between the range 410-680N of in machining nimonic C-263 alloy under
different levels of machining parameters using whisker reinforced ceramic
insert.
(a) 3D response surface plots for cutting force at depth of cut of 0.75 mm
(b) 3D response surface plots for cutting force at feed rate of 0.102
mm/rev
217
(c) 3D Response Surface Plots for Cutting Force at Cutting Speed of 190
m/min
Figure 5.38 (a-c) 3D Response Surface Plots for Cutting Force using
Whisker Reinforced Ceramic Insert
650
600
550
500
450
400
Cutting speed = 125 m/min
350 Cutting speed = 190 m/min
300 Cutting speed = 250 m/min
250
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.39 Effect of feed rate on cutting force at different cutting speeds
218
Figure 5.41 shows that the cutting force tends to increase, when the
feed rate and depth of cut increases. The maximum cutting force of 620 N is
observed at high level of depth of cut and feed rate.
650
600
550
500
450
400 feed rate = 0.051 mm/rev
350 feed rate = 0.102 mm/rev
300 feed rate = 0.143 mm/rev
250
0.5 0.75 1
Depth of cut (mm)
600
0.35
550
0.25
500
450 0.15
Cutting force
flank wear
400 0.05
0.051 0.102 0.143
Feed rate (mm/rev)
Figure 5.42 Effect of Feed Rate on Cutting Force and Flank Wear at
cutting speed of 190 m/min and depth of cut of 0.75 mm
Figure 5.43 (a-c) illustrates the contour maps in the feature plane
for temperature at tool tip at different depths of cut. These response contours
can help in the prediction of the temperature rise at tool tip at any zone of the
experimental domain.
220
Figure 5.44 (a-c) illustrates the 3D response surface plots for the
temperature rise at tool tip. These surface plots are drawn, using the
developed RSM model by varying the two different parameters and keeping
the third parameter at the middle level. It is clear from this Figure 5.44 (a-c)
that the temperature rise at tool tip is high at higher cutting speed and feed
rate. The temperature at the tool tip is reduced when the level of depth of cut
and feed rate is reduced. It is found that the temperature at tool tip varies
between the range of 365-720°C in machining nimonic C-263 alloy under
different levels of machining parameters using the whisker reinforced ceramic
insert.
(a) 3D response surface plots for temperature at tool tip at depth of cut
of 0.75 mm
(b) 3D response surface plots for temperature at tool tip at cutting speed
of 190 m/min
222
(c) 3D response surface plots for temperature at tool tip at feed rate of
0.102 mm/rev
Figure 5.44 (a-c) 3D response surface plots for temperature at tool tip
using Whisker Reinforced Ceramic Insert
700
625
550
475
400 Cutting speed = 125 m/min
Cutting speed = 190 m/min
325 Cutting speed = 570 m/min
250
0.05 0.102 0.143
Feed rate (mm/rev)
700
625
550
475
400 depth of cut = 0.50 mm
depth of cut = 0.75 mm
325 depth of cut = 1 mm
250
125 190 250
Cutting speed (m/min)
700
625
550
475
400 feed rate = 0.051 mm/rev
325 feed rate = 0.102 mm/rev
feed rate = 0.143 mm/rev
250
0.5 0.75 1
Depth of cut (mm)
Figure 5.48 (a-c) illustrates the contour maps in feature plane for
surface roughness at different depths of cut, the surface roughness at any zone
of the experimental domain can be predicted.
(c) 3D response surface plots for surface roughness at feed rate of 0.102
mm/rev
Figure 5.49 (a-c) 3D Response Surface Plots for Surface Roughness using
Whisker Reinforced Ceramic Insert
Figure 5.50 shows the effect of the feed rate at different cutting
speeds on the surface roughness. From the illustration, it is seen that an
increase in the feed rate results in an increase surface roughness. However,
the surface roughness is reduced with the increase in the cutting speed. At a
higher feed rate the height of the ridges (roughness) is increased, thus
contributing to a higher surface roughness.
227
Figure 5.51 shows the effect of the feed rate and the depth of cut on
the surface roughness. From the illustration, it is seen that the increase in the
feed rate increases the surface roughness, whereas the best surface roughness
is observed at a high level of the depth of cut and a low level of the feed rate.
It is seen that at a higher depth of cut, a reduction in the surface roughness is
observed. This is because, at a higher depth of cut, the surface layer may get
work hardened, thus leading to a reduction in the surface roughness.
2
feed rate = 0.051 mm/rev
feed rate = 0.102 mm/rev
feed rate = 0.143 mm/rev
1
0.5 0.75 1
Depth of cut ( mm)
Figure 5.52 show that the increase in the depth of cut and cutting
speed reduces the surface roughness. The surface roughness observed for the
combination of depth of cut and cutting speed is lower than the surface
roughness observed for the combination of low level of depth of cut and
cutting speed. It can be realized that the high level of depth of cut and cutting
speed gives the best possible cut.
The significance of the feed rate is higher followed by the cutting speed
and depth of cut on surface roughness. Further, it is noted that the rubbing of the
wornout tool on the work piece associates the change in the surface roughness.
This is clearly shown in Figure 5.53 (a-c), in which the surface roughness tends to
increase, as the flank wear increases at all levels of the cutting speed. In
addition, the low thermal conductivity of the nimonic C-263 alloy contributes to
the accumulation of heat at the tool-work contact zone.
229
0.4 4
0.35
0.3 3.5
0.25
3
0.2
0.15 flank wear
2.5
Surface roughness
0.1
0.05 2
0.051 0.102 0.143
Feed rate (mm/rev)
(a) Effect of feed rate on flank wear and surface roughness at cutting
speed of 125 m/min and depth of cut of 0.75 mm
0.4 4
0.35
0.3 3.5
0.25
3
0.2
0.15 2.5
0.1 Cutting force
Surface roughness
0.05 2
0.051 0.102 0.143
Feed rate (mm/rev)
(b) Effect of feed rate on flank wear and surface roughness at cutting
speed of 190 m/min and depth of cut of 0.75 mm
230
0.5 4
0.45
0.4 3.5
0.35
0.3 3
0.25 2.5
0.2
0.15 2
flank wear
0.1 Surface roughness
0.05 1.5
0.051 0.102 0.143
Feed rate (mm/rev)
(c) Effect of feed rate on flank wear and surface roughness at 250 m/min
cutting speed and depth of cut of 0.75 mm
Figure 5.53 (a-c) Effect of Feed Rate on Flank Wear and Surface
Roughness at all level of Cutting Speed for Whisker
Reinforced Ceramic Insert
Figure 5.55 (a-c) illustrates the contour maps in feature plane for
flank wear at different depths of cut, which can help in the prediction of the
flank wear at any zone of the experimental domain.
Figures 5.56 (a-c) illustrate the 3D response surface plots for the
flank wear. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is clear that the lowest flank wear is obtained at the middle
level of the cutting speed, and low level of feed rate and depth of cut. It is
234
found that the flank wear varies between the range of 0.24-0.435 mm in
machining nimonic C-263 alloy under different level of machining parameters
using the whisker reinforced ceramic insert.
(a) 3D response surface plots for flank wear at 0.75 mm depth of cut
(b) 3D response surface plots for flank wear at 190 m/min cutting speed
(c) 3D response surface plots for flank wear at 0.102 mm/rev feed rate
Figure 5.56 (a-c) 3D Response Surface Plots for Flank Wear using
Whisker Reinforced Ceramic Insert
235
Figure 5.57 shows the effect of the feed rate at different cutting
speeds on the progression of flank wear. From the illustration, it is observed
that the rate of progression of the flank wear is relatively more with the feed
rate than with the cutting speed, signifying the better tolerance of the whisker
reinforced ceramic insert to higher speed.
The better tolerance to the higher cutting speed could be mainly due
to the higher hot hardness property of the ceramic insert. In addition, it also
shows that feed rate control is more important than cutting speed control,
while turning the nimonic C-263 alloy, using a whisker reinforced ceramic
insert. Further, Figure 5.57 indicates that the lowest flank wear results at the
middle level of the cutting speed and low level of the feed rate.
0.5
0.4
0.3
Figure 5.58 indicates that the flank wear increases with an increase
in the depth of cut. The flank wear is considerably lower with an increase in
the cutting speed than with the depth of cut. The increase in the flank wear
with increased depth of cut could be due to the progressive damage of the
cutting edge, and the corresponding increase in contact between the tool edge
and the machined surface. This result indicate that the frictional heat
generated due to contact between the wornout tool and the work material is
more significant than the heat generation due to an increase in the cutting
236
speed, while machining the nimonic C-263 alloy. Further, Figure 5.58
indicates that the occurrence of a lower flank wear at a middle level of the
cutting speed and lower level of the depth of cut.
0.5
0.45
0.4
0.35
0.3
0.25
0.2 depth of cut = 0.50 mm
0.15 depth of cut = 0.75 mm
depth of cut = 1 mm
0.1
125 190 250
Cutting speed (m/min)
Figure 5.59 indicates that the flank wear increases with the increase
feed rate and depth of cut. However, the increase in the flank wear is
relatively more with the feed rate than with the depth of cut. At a high feed
rate and high depth of cut, the flank wear observed is 0.40 mm, which is
considerably higher than the flank wear value of 0.29 mm observed at a low
feed rate and low depth of cut. Figures 5.57 - 5.59 show the effect of the
selected parameters on the progression of the flank wear.
0.5
0.4
0.3
Figure 5.59 Effect of Depth of Cut on Flank Wear at Different Feed Rates
237
The results show that the influence of the feed rate and depth of cut
is more significiant while machining the nimonic C-263 alloy with a whisker
reinforced ceramic insert. The change in the geometry of the cutting edge can
be seen distinctly from the SEM micrograph shown in Figure 5.60. The EDS
pattern shown in Figure 5.61 confirms that besides oxygen, the transferred
layer consists of traces of work piece elements such as Ni, Ti, Al, Mo, Cr and
Co. The EDS analysis of the worn out insert was also conducted at a location
indicated by the mark in the SEM image, to confirm the transfer of the
composition as shown in Figure 5.61.
Figure 5.60 SEM Micrograph of the worn region of the cutting edge.
Cutting conditions:V- 250m/min,S-0.143mm/rev, a p-0.75mm
Figure 5.61 EDS Analysis which Examined the Marked Cross Hair
Point in the Cutting Edge
238
(a) Worn out insert at cutting (b) Worn out insert at cutting
speed of 250m/min, feed rate of speed of 190 m/min, feed rate
0.143 mm/rev and depth of of 0.102 mm/rev and depth
cut of 1mm of cut of 1mm
(c) Worn out insert at cutting (d) Worn out insert at cutting
speed of 125 m/min, feed rate of speed of 125 m/min, feed rate of
0.102 mm/rev and depth of cut of 0.143 mm/rev and depth of cut
0.75 mm of 0.75mm
The experimental results and RSM modelled values for the cutting
force, temperature at tool tip, surface roughness and flank wear in machining
nimonic C-263 alloy using whisker reinforced ceramic insert is shown in
Table 5.5. From the Table 5.5, a good aggrement is obtained between the
actual experimental results and predicted values based on RSM model,
indicating the effectiveness of prediction of cutting force, temperature at tool
tip, surface roughness and flank wear with 95% confidence levels during the
machining of the nimonic C-263 alloy using whisker reinforced ceramic
insert.
The average percentage error for the responses such as the cutting
force, temperature at tool tip, surface roughness and flank wear between the
experimental and RSM model values were 1.90%, 2.69%, 3.75%, and 1.74%
respectively.
240
as cutting force, temperature at tool tip, surface roughness and flank wear
with ANN model seems to have reasonable good prediction potential while
machining nimonic C-263 alloy using whisker reinforced ceramic insert.
Further, ANN model takes lesser computational time while giving better
accuracy. The models designed by ANN and RSM models would be helpful
to predict these responses during machining of the nimonic C-263 alloy using
whisker reinforced ceramic insert.
9
8 Fz Ra VB
7
6
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627
Experiment Number
(a) Percentage error between the experimental results and RSM predicted Values for
whisker reinforced ceramic insert
12
11 Fz Ra VB
10
9
8
7
6
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 10 1112131415 16 171819202122 23 24 252627
Experiment Number
(b) Percentage error between the Experimental results and ANN predicted Values for
whisker reinforced ceramic insert
Figure 5.63 (a-b) Percentage Error Among the Experimental results, RSM
and ANN Predicted Values for Whisker Reinforced Ceramic
Insert
243
1 181 0.05 0.57 422 420 456 450 2.53 2.65 0.25 0.23
2 181 0.05 0.57 422 415 456 460 2.53 2.50 0.25 0.22
3 181 0.05 0.57 422 425 456 465 2.53 2.48 0.25 0.24
In this research work, an attempt has also been made to monitor the
status of the whisker reinforced ceramic insert by acquiring AE signal while
turning nimonic C-263 alloy at different cutting speed and feed rate at
constant depth of cut.
244
The Figure 5.64 (a-f) shows the Acoustic Emission (AE) signals
when turning the nimonic C-263 alloy at different cutting conditions. When
turning the nimonic C-263 alloy at cutting speeds of 125 m/min and 190
m/min with feed rates of 0.102 mm/rev and 0.143 mm/rev, the cutting edge
undergoes running in wear significantly thus responding with spreaded
frequency acoustic emission around in the range of 40-100 kHz with low FFT
magnitude as seen from the Figure 5.64 (a-d) by the presence of dominant
peaks.
Also when the tool is sharp the chip breakage will be better there
by producing a smaller magnitude signal as there is gradual and uniform tool
flank wear. The occurrence of higher amplitude frequency components in the
lower range FFT magnitude indicates the wearing of tool. When the tool
fracture occurs, the tool damage is signified with production of strong AE
signal, correspondingly very large and wide frequency components are seen
even beyond 400 kHz, together with low frequency components as seen in the
Figures 5.64 (a-d).
Due to this, the energy of the signal produced when turning the
nimonic C-263 alloy using whisker reinforced ceramic insert is high as seen
from the Figures 5.64 (e to f), i.e. the signal is spread in wider range, than at
lower combinations of cutting conditions. As tool flank wear increases, an
increase in the amplitude of the signal seen with high FFT magnitude. Apart
from the occurrence of low frequency components of 40-100 kHz as seen
from the lower cutting conditions, dominant peaks are also seen at frequencies
of 150 kHz, 200 kHz, 250 kHz, 300 kHz, and 400 KHz which may possibly
due to higher order stressing of the material at higher cutting speed indicating
worn out status of the whisker reinforced ceramic tool insert.
Figure 5.65 (a-c) illustrates the contour maps in feature plane for
each of the cutting force at different depths of cut. These response contours
can help in the prediction of the cutting force at any zone of the experimental
domain.
Figure 5.66 (a-c) illustrates the 3D response surface plots for the
cutting force. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is clear from these figures that the cutting force is high at
lower cutting speed and at a higher feed rate. The cutting force is reduced
when the level of depth of cut and feed rate is reduced. It is found that the
cutting force (Fz) varies between the range 265-550 N when machining
nimonic C-263 alloy under different level of machining parameters using
cubic boron nitride insert.
(a) 3D response surface plots for cutting force at 0.50 mm depth of cut
250
(b) 3D response surface plots for cutting force at 125 m/min cutting speed
(c) 3D response surface plots for cutting force at 0.096 mm/rev feed rate
Figure 5.66 (a-c) 3D Response Surface Plots for Cutting force using
Cubic Boron Nitride Insert
525
450
375
300
depth of cut = 0.25 mm
225 depth of cut = 0.50 mm
depth of cut = 0.75 mm
150
80 125 190
Cutting speed (m/min)
550
500
450
400
350
300
250 Cutting speed = 80 m/min
Cutting speed = 125 m/min
200 Cutting speed = 190 m/min
150
0.055 0.096 0.159
Feed rate (mm/rev)
Figure 5.68 Effect of Feed Rate on Cutting Force at Different Cutting
Speeds
252
525
450
375
300 feed rate = 0.055 mm/rev
feed rate = 0.096 mm/rev
225 feed rate = 0.159 mm/rev
150
0.25 0.5 0.75
Depth of cut (mm)
Figure 5.69 Effect of Depth of Cut on Cutting Force at Different Feed Rates
At a higher feed rate the cutting force increases as the flank wear
increases, which are evidently seen in Figure 5.70. The increase in the flank
wear at a higher feed rate is due to the damage of the cutting edge, creating
the abrasion between the tool edge and work piece surface, thus the
generation of the cutting force is also high.
500
0.35
450
0.25
400
350 0.15
Cutting force
flank wear
300 0.05
0.055 0.096 0.159
Feed rate (mm/rev)
Figure 5.70 Effect of Feed Rate on Cutting Force and Flank Wear at
cutting speed of 125 m/min and depth of cut 0.50 mm
253
Figure 5.71 (a-c) illustrates the contour maps in feature plane for
temperature at tool tip at different depths of cut. These response contours can
help in the prediction of the temperature rise at tool tip at any zone of the
experimental domain.
Figure 5.72 (a-c) illustrates the 3D response surface plots for the
temperature rise at tool tip. It is clear from these figures that the temperature
rise at tool tip is high at higher cutting speed and feed rate. The temperature at
tool tip gets reduced when the level of depth of cut and feed rate is reduced. It
is found that the temperature at tool tip varies between the range of 390-
740°C while machining nimonic C-263 alloy under different level of
machining parameters using the cubic boron nitride insert.
(a) 3D response surface plots for temperature at tool tip at 0.50 mm depth of cut
255
(b) 3D response surface plots for temperature at tool tip at 0.096 mm/rev feed rate
(c) 3D response surface plots for temperature at tool tip at 125 m/min cutting speed
725
650
575
500 Cutting speed = 80 m/min
Cutting speed = 125 m/min
425 Cutting speed = 190 m/min
350
0.055 0.096 0.159
Feed rate (mm/rev)
700
625
550
depth of cut = 0.25 mm
475 depth of cut = 0.50 mm
depth of cut = 0.75 mm
400
80 125 190
Cutting speed (m/min)
700
650
600
550
500 feed rate = 0.055 mm/rev
feed rate = 0.096 mm/rev
450 feed rate = 0.159 mm/rev
400
0.25 0.5 0.75
Depth of cut (mm)
Figure 5.76 (a-c) illustrates the contour maps in feature plane for
surface roughness at different depths of cut, which can help in the prediction
of the surface roughness at any zone of the experimental domain.
(a) 3D response surface plots for surface roughness at 0.50 mm depth of cut
(b) 3D response surface plots for surface roughness at 0.096 mm/rev feed rate
(c) 3D response surface plots for surface roughness at 125 m/min cutting speed
Figure 5.78 shows the effect of the feed rate at different cutting
speeds on the surface roughness. From the illustration, it is observed that as
feed rate increases the surface roughness increases. However, the surface
roughness reduced while increasing the cutting speed.
3.5
3
2.5
2
Cutting speed = 80 m/min
1.5 Cutting speed = 125 m/min
Cutting speed = 190 m/min
1
0.25 0.5 0.75
Feed rate ( mm/rev)
Figure 5.78 Effect of Feed rate on Surface Roughness at Different
Cutting Speeds
Figure 5.79 shows the effect between the feed rate and the depth of
cut on the surface roughness. From the illustration, it is seen that the increase
in the feed rate increases the surface roughness, whereas relatively better
surface roughness is observed at the combination of higher level of the depth
of cut and a lower level of the feed rate. It is observed for higher depth of cut,
a reduction in the surface roughness. This is because, at a higher depth of cut,
the surface layer may get work hardened, thus leading to a reduction in the
surface roughness.
3.5
3
2.5
2
feed rate = 0.055 mm/rev
1.5 feed rate = 0.096 mm/rev
feed rate = 0.159 mm/rev
1
0.25 0.5 0.75
Depth of cut ( mm)
Figure 5.79 Effect of Depth of Cut on Surface Roughness at Different
Feed Rates
261
Figure 5.80 shows that the increase in the depth of cut and cutting
speed reduces the surface roughness. The surface roughness observed at a
higher level of depth of cut and cutting speed is lower than the surface
roughness observed at a lower level of depth of cut and cutting speed.
3.5
3
2.5
2
1.5 depth of cut = 0.25 mm
1 depth of cut = 0.50 mm
depth of cut = 0.75 mm
0.5
80 125 190
Cutting speed ( m/min)
The higher significance of the feed rate over cutting speed and
depth of cut indicates the rubbing of the worn flank, and the associated
change in the surface roughness. This is clearly shown in Figure 5.81 (a-c), in
which the surface roughness tends to increase, as the flank wear rate increases
at all levels of the cutting speed. In addition, the low thermal conductivity of
the nimonic C-263 alloy contributes to the generation of heat in the tool work
contact zone.
(a) Effect of feed rate on flank wear and surface roughness at cutting
speed of 80m/min and depth of cut of 0.50 mm
262
0.4 3.9
0.35
3.4
0.3
0.25 2.9
0.2 2.4
0.15
0.1
Cutting force 1.9
Surface roughness
0.05 1.4
0.055 0.096 0.159
Feed rate (mm/rev)
(b) Effect of feed rate on flank wear and surface roughness at cutting
speed of 125 m/min and depth of cut of 0.50 mm
0.5
3.2
0.4
2.7
0.3
2.2
flank wear
0.2 Surface roughness 1.7
0.1 1.2
0.055 0.096 0.159
(c) Effect of feed rate on flank wear and surface roughness at cutting
speed of 190 m/min and depth of cut of 0.50 mm
Figure 5.81 (a-c) Effect of Feed Rate on Flank Wear and Surface
Roughness at All Level of Cutting Speed for Cubic Boron
Nitride Insert
263
Figure 5.83 (a-c) illustrates the contour maps in feature plane for
flank wear at different depths of cut, which can help in the prediction of the
flank wear at any zone of the experimental domain.
265
Figures 5.84 (a-c) illustrate the 3D response surface plots for the
flank wear. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is also clear from these figures that the lowest flank wear is
obtained at the middle level of the cutting speed, and lower level of feed rate
and depth of cut. It is observed that the flank wear varies between the range of
0.29-0.48 mm while machining nimonic C-263 alloy under different levels of
machining parameters using the cubic boron nitride insert.
(a) 3D response surface plots for flank wear at 0.50 mm depth of cut
(b) 3D response surface plots for flank wear at 0.096 mm/rev feed rate
267
(c) 3D response surface plots for flank wear at 125 m/min cutting speed
Figure 5.84 (a-c) 3D Response Surface Plots for Flank Wear using Cubic
Boron Nitride Insert
Figure 5.85 shows the effect of the feed rate at different cutting
speeds on the progression of flank wear. From the illustration, it is observed
that the rate of progression of the flank wear is more with the feed rate than
with the cutting speed. The lowest flank wear is observed at middle level of
the cutting speed and low level of the feed rate.
0.5
0.4
0.3
Cutting speed = 80 m/min
0.2 Cutting speed = 125 m/min
Cutting speed = 190 m/min
0.1
0.055 0.096 0.159
Feed rate (mm/rev)
Figure 5.86 indicates that the flank wear increases with an increase
in the depth of cut. The increase in flank wear is considerably lower with an
increase in the cutting speed than with the depth of cut. The increase in the
flank wear with increased depth of cut could be attributed to the progressive
268
damage of the cutting edge, and the corresponding increase in contact area
between the cutting edge and the machined work surface. The lower flank
wear is observed at middle level of the cutting speed and lower level of the
depth of cut.
0.5
0.45
0.4
0.35
0.3
0.25
0.2 depth of cut = 0.25 mm
0.15 depth of cut = 0.50 mm
depth of cut = 0.75 mm
0.1
80 125 190
Cutting speed (m/min)
Figure 5.87 indicates that the flank wear increases with the feed
rate and depth of cut. However, the rate of increase of the flank wear is more
significant with the feed rate than with the depth of cut. At a higher feed rate
and higher depth of cut, the observed flank wear is 0.42 mm, which is
considerably higher than the flank wear value of 0.33 mm observed at a low
feed rate and low depth of cut.
0.5
0.4
0.3
0.2 feed rate = 0.055 mm/rev
feed rate = 0.096 mm/rev
feed rate = 0.159 mm/rev
0.1
0.25 0.5 0.75
Depth of cut (mm)
Figure 5.87 Effect of Depth of Cut on Flank Wear at Different Feed Rates
269
The results show that the influence of the cutting speed and feed
rate is more significant process parameter while machining the nimonic C-263
alloy with a cubic boron nitride insert. The change in the geometry of the
cutting edge when machining the nimonic C-263 alloy at different cutting
conditions can be seen distinctly from the SEM micrograph given in
Figure 5.88. The wear mechanisms observed in the machining of the nimonic
C-263 alloy using a cubic boron nitride insert are micro chipping, adhesion as
evident in the Figure 5.88 (a-d).
(a)SEM Micrograph of the Worn out (b)SEM Micrograph of the Worn out
Cutting Edge at Cutting speed of Cutting Edge at Cutting speed of
190m/min, feed rate of 0.159 mm/rev 190m/min, feed rate of 0.096 mm/rev
and depth of cut of 0.75mm and depth of cut of 0.75mm
Figure 5.88 (a-d) SEM Micrograph of the Worn Out Cutting Edge at
Different Cutting Conditions using Cubic Boron Nitride
Insert
270
The experimental results and RSM modelled values for the cutting
force, temperature at tool tip, surface roughness and flank wear in machining
nimonic C-263 alloy using cubic boron nitride insert is shown in Table 5.8.
From the Table 5.8, a good aggrement is obtained between the actual
experimental results and predicted values based on RSM model, indicating
the effectiveness of prediction of cutting force, temperature at tool tip, surface
roughness and flank wear with 95% confidence levels during the machining
of the nimonic C-263 alloy using cubic boron nitride insert.
Table 5.8 Experimental and Model Results for Cubic Boron Nitride
Insert
1 134 0.06 0.25 279 275 508 520 2.16 2.25 0.29 0.25
2 134 0.06 0.25 279 270 508 515 2.16 2.00 0.29 0.26
3 134 0.06 0.25 279 280 508 225 2.16 2.30 0.29 0.28
As seen from all the Figures 5.90 - 5.92, the level of microhardness
of the machined surface also significantly increases with the machining time.
With an increase in the cutting time, the tool wear progressively grows, thus
inducing higher frictional contact between the tool and the work-piece,
ultimately leading to pressure induced plastic deformation rather than shear
deformation.
work hardening, high cutting resistance and high localized temperature near
the tool work interface, which greatly contributes to residual stresses during
machining. In this study, residual stress measurements were made three times
at each point on the machined surface with respect to all cutting conditions
after finite time intervals of 3 min, 6 min, and 9 min. The typical Residual
Stress (RS) patterns produced in the cutting direction, while turning the
nimonic C-263 alloy in different cutting conditions, using PVD coated
carbide inserts are illustrated in Figures 5.93 - 5.95.
In all the cases it is found, that the residual stresses are more tensile
at the surface of the work-piece and become compressive as the depth of the
work-piece increases. The external residual stresses on the machined surface
are all tensile residual stresses, as the thermal loads prevail against the
mechanical loads, whereas the subsurface does not (Berruti et al 2009).The
external surface is plastified by compression. When cooling, the external
surface tends to recover its position, which is no longer possible due to plastic
deformation, leading to a tensile state. As illustrated in Figure 5.93, when the
tool is fresh, the maximum values of the surface tensile residual stresses of
about 100 MPa and 175MPa are recorded, while turning at the feed rates of
0.102 mm/rev and 0.143 mm/rev respectively, at a cutting speed of 22 m/min.
As the tool wears out, i.e., after cutting for 9min, the surface tensile residual
stresses rise to about 300MPa and 400MPa, with respect to feed rates of 0.102
mm/rev and 0.143mm/rev.
During the exposure to intense heat fluxes near the primary shear
zone and in the rubbing zone, a high temperature gradient exists, which may
lead to the local plastification of the work material. When the surface returns
to a steady state at room temperature, the tensile stresses remain at the
surface. Consequently, compressive stresses exist in the sub-surface. Further,
the residual stresses near the surface shifted towards compression as the feed
279
rate was increased, thus indicating the dominance of the mechanical load.
This is observed when the tool is fresh. However, such an effect is not
observed when the tool is used for a period of 9min thus diminishing the feed
rate effect, and instead, the prevalence of the tensile residual stress is more,
which indicates the dominance of the thermal load over the mechanical load.
From the Figure 5.94, it is observed that, as the cutting speed is increased, the
level and depth of the tensile residual stress increases. When the cutting speed
is increased, the generation of temperature increases, thus favouring the
thermal load.
500
S = 0.102mm/rev, t = 3 min
400 S = 0.102 mm/rev, t = 6 min
S = 0.102 mm/rev, t = 9 min
300 S = 0.143 mm/rev, t = 3 min
S = 0.143 mm/rev, t = 6 min
200 S = 0.143 mm/rev, t = 9 min
100
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
-200
-300
-400
-500
Depth beneath the surface (mm)
Figure 5.93 Residual Stresses at Cutting Speed of 22 m/min
281
800
S= 0.102 mm/rev, t = 3 min
S= 0.102 mm/rev, t = 6 min
600 S= 0.102 mm/rev, t = 9 min
S= 0.143 mm/rev, t = 3 min
400 S= 0.143 mm/rev, t = 6 min
S= 0.143 mm/rev, t = 9 min
200
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
-200
-400
Depth beneath the surface (mm)
The high pressures developed between the tool and the work piece
during turning, produce a stressed layer of deformed metal on the surface of
the work, and the deformation causes a hardening effect. The decrease in
hardening below the surface could be due to the neutralisation of the heat and
strain effects below the machined surface. The higher microhardness values
just underneath the machined surface could be attributed to the pile up of the
dislocation density due to plastic deformation. Particularly, in the case of the
nimonic C 263 alloy, the presence of higher percentage chromium and
molybdenum strengthens the grain boundaries with the formation of complex
metallic carbides, such as M6C and M23C6, and the high cobalt content (19-
21%) strengthens the material by solution hardening, which impedes the
movement of dislocation, thus inducing higher plastic deformation.
It is also observed from Figures 5.96 (a-c) that, the hardness values
increased with increasing feed rate. At a higher feed rate, the load on the
cutting edge increases, thus inducing higher deformation and surface
hardness. Apart from the cutting parameters, the changes in the status of the
cutting edge due to cutting time, viz. tool wear, also inflict alterations in the
machined surface. As seen from the Figure 5.96 (a-c), the level of
microhardness of the machined surface also significantly increases with the
machining time. With an increase in the cutting time, the tool wear
progressively grows, thus inducing higher frictional contact between the tool
and work piece, ultimately leading to pressure induced plastic deformation
rather than shear deformation.
700
S = 0.102 mm/rev, t = 3 min
650
S = 0.102 mm/rev, t = 6 min
600 S = 0.102 mm/rev, t = 9 min
S = 0.143 mm/rev, t = 3 min
550 S = 0.143 mm/rev, t = 6 min
S = 0.143 mm/rev, t = 9 min
500
450
400
350
300
250
0.05 0.15 0.25 0.35 0.45 0.55 0.65
Depth beneath the surface (mm)
700
S = 0.102 mm/rev, t = 3 min
650 S = 0.102 mm/rev, t = 6 min
S = 0.102 mm/rev, t = 9 min
600
) S = 0.143 mm/rev, t = 3 min
V 550 S = 0.143 mm/rev, t = 6 min
H
( S = 0.143 mm/rev, t = 9 min
ss 500
e
n
d 450
ra
h
o 400
rc
i 350
M
300
250
0.05 0.15 0.25 0.35 0.45 0.55 0.65
Depth beneath the surface (mm)
800
750 S= 0.102 mm/rev, t = 3 min
S= 0.102 mm/rev, t = 6 min
700 S= 0.102 mm/rev, t = 9 min
650 S= 0.143 mm/rev, t = 3 min
600 S= 0.143 mm/rev, t = 6 min
S= 0.143 mm/rev, t = 9 min
550
500
450
400
350
300
250
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
Depth beneath the surface (mm)
Figure 5.97 TEM Bright Field Images Showing the M23C6 type Carbides
at the Grain Boundary (Ankamma et al 2011)
In all the cases, it is found that the residual stresses are more tensile
at the surface of the work piece and become compressive as the depth of the
work piece increases. Then, after approximately 0.6mm depth, the residual
stresses diminish. Nimonic C-263 material has low thermal conductivity
(11.72W/m°C), which is about one third of the whisker reinforced ceramic
cutting material (35.2W/m°C), and therefore, a lot of thermal choking takes
place at the tool work interface, thus resulting in plastic deformation induced
by thermal load (without phase transformation). The external residual stress is
287
tensile, because the surface expands greatly during heating, whereas the
subsurface does not. The external surface is plastified by compression. When
cooling, the external surface tends to recover its position, which is no longer
possible due to the plastic deformation, leading to a tensile state.
During the exposure to intense heat fluxes near the primary shear
zone and in the rubbing zone, a high temperature gradient exists, which may
lead to the local plastification of the work material. When the surface returns
to a steady state at room temperature, the tensile stresses remain at the
surface. Consequently, the compressive stresses exist in the sub-surface.
Further, the residual stresses near the surface shifted towards compression as
the feed rate is increased, thus indicating the dominance of the mechanical
load (uncut chip thickness). This is observed when the tool is fresh. However,
such an effect is not observed when the tool is used for a period of 9min, thus
diminishing the feed rate effect; instead, the prevalence of the tensile residual
stress is more, which indicates the dominance of the thermal load over
mechanical load.
From illustrations 5.98 and 5.99, it is seen that, as the cutting speed
is increased, the level and depth of the tensile residual stress increases. When
the cutting speed is increased, the temperature increases, thus favouring
thermal load. The maximum values of the surface tensile residual stresses are
about 725MPa and 850MPa, with respect to the feed rate of 0.102 mm/rev
288
The cutting edge and the rake angle are predominant factors
controlling the distribution of stresses in the subsurface layer. In this study, a
ceramic insert cutting tool having a negative rake (-6°) with ‘T’ land cutting
edge, and 0.8mm nose radius, is used for turning. Generally, the compressive
zone expands visibly when cutting with a rounded cutting edge and larger
negative rake angles. As a consequence, in such cases, the work-hardening
effect will probably be more intense due to the plowing effect. But due to its
lower thermal conductivity of the ceramic insert tool when compared to the
nimonic C-263 alloy, the most of the heat generated is conducted through the
work material, resulting in thermal load. However, the resultant load is
thermal, and hence, higher tensile RS are observed.
800
700 f = 0.102mm/rev, t = 3 min
f = 0.102mm/rev, t = 6 min
600 f = 0.102mm/rev, t = 9 min
500 f = 0.143mm/rev, t = 3 min
f = 0.143mm/rev, t = 6 min
400 f = 0.143mm/rev, t = 9 min
300
200
100
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
-200
-300
-400
-500
Depth beneath the surface (mm)
1000
900 f = 0.102mm/rev, t = 3 min
800 f = 0.102mm/rev, t = 6 min
f = 0.102mm/rev, t = 9 min
)a 700 f = 0.143mm/rev, t = 3 min
P600 f = 0.143mm/rev, t = 6 min
M
( f = 0.143mm/rev, t = 9 min
se 500
ss 400
er
ts 300
la
u 200
d
is
e 100
R
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
-200
-300
-400
Depth beneath the surface (mm)
1000
900 f = 0.102mm/rev, t = 3 min
800 f = 0.102mm/rev, t = 6 min
f = 0.102mm/rev, t = 9 min
700 f = 0.143mm/rev, t = 3 min
600 f = 0.143mm/rev, t = 6 min
500 f = 0.143mm/rev, t = 9 min
400
300
200
100
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
-200
-300
-400
Depth beneath the surface (mm)
5.16 SUMMARY