Indian Journal of Science and Technology
DOI: 10.17485/ijst/2019/v12i19/143902
Year: 2019, Volume: 12, Issue: 19, Pages: 1-16
Original Article
Manoj Nayak1* and Rakesh Sehgal2
Manoj Nayak1* and Rakesh Sehgal2
1Department of Mechanical Engineering, Manav Rachna International Institute of Research and [email protected]
2Department of Mechanical Engineering, National Institute of Technology, [email protected]
*Author For Correspondence
Manoj Nayak
1Department of Mechanical Engineering, Manav Rachna International Institute of Research and Studies, Sector 43, Faridabad - 121004, Haryana, India;
Email: [email protected]
Objectives: This study aims at providing solution to shop floor engineers on parametric selection of hard machining during reconditioning of damaged tools and dies after a certain period of life. Methods/Statistical Analysis: Experiments were conducted for hard turning of continuous and interrupted surfaces using Cubic Boron Nitride (CBN) tools on a highly automated all geared lathe using force dynamometer and surface roughness tester. In this experiment the influence of cutting speed, feed and CBN tool material properties on main cutting force, thrust force, surface roughness and cutting temperature has been experimentally investigated in continuous and interrupted turning. A total of 54 experiments were conducted for both continuous and interrupted surfaces and standard statistical methodology is applied. Findings: Statistical checks (ANOVA analysis, R2 statistics, p-values) indicated that the models were adequate. Thrust force is higher and surface finish is better in case of interrupted cutting as compared to continuous cutting. The results also showed that the feed strongly influences the main cutting force and surface roughness; cutting speed strongly influences the cutting temperatures; feed strongly influence the surface roughness in both continuous and interrupted machining. The predicted responses were close to the experimental values and the proposed experimental models can be used to improve the hard turning processes. Chipping of the cutting edge was predominantly found in continuous turning but did not occur in interrupted turning at 102 m/min. The tools failed mechanically at very low speed in both the cases. Abrasion, adhesion, diffusion and chemical wear are the different wear mechanisms observed during hard turning of AISI D6 steel. Application/Improvements: This research establishes the capability of hard turning as an alternative to grinding process so as to avoid use of cutting fluid due environmental hazards. By selecting proper process parameters of speed, feed and depth of cut, selection of tool grade, dry hard turning can be accomplished economically.
Keywords: Continuous, Cutting Force, Hard Turning, Interrupted, Surface Roughness
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