Optimization of Turning Process Parameters for Mild Steel

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 11, 2016 | ISSN (online): 2321-0613

Optimization of Turning Process Parameters for Mild Steel Prof. Alpesh R. Patel1 Prof. Lalit S. Patel2 Prof. Tejas C. Patel3 1,3 Assistant Professor 2Research Scholar 1 Government Engineering College, Valsad, Gujarat, India 2Rai University, Ahmedabad, Gujarat, India 3 Shree Swami Atmanand Saraswati Institute of Technology, Surat, Gujarat, India Abstract— The present research paper is focused on the analysis of optimum cutting conditions to get lowest cutting forces in turning of mild steel material. The experimental result analysis showed that the optimum combination of various input factors as type of insert type, work piece material, Approach Angle, feed and depth of cut. Further, the confirmation tests are conducted and the results are found to be increased with increment of feed and depth of cut.

Key words: Turning, Mild Steel, Lathe Machine, Cutting Forces, Optimization

Other tool geometry will be kept constant.

Tool material will also be kept same.

II. MACHINES/ INSTRUMENTS REQUIRED The details of machines and equipment available in workshop on which the project will be carried out are given below: A. Lathe Machine:

I. INTRODUCTION This project is on the analysis of the effect in change of different parameters in turning process. The various parameters that are important in turning are, A. Machining Feed: There are different feeds available on the lathe machine, which are varied to determine the effect of feed on the cutting forces.

B. Depth of Cut: The depth of cut can be varied with the help of micrometer dial on the cross-slide.

C. Approach Angle: Different approach angles will be taken for the analysis.

Type

Range of speeds (RPM)

HMT Lathe

32,52,88,150,250,420 710,1200

Fig. 1: Lathe Machine

Range of feed Main motor Table feed motor(hp) [0.05,0.06,0.07,0.10,0.13,0.15] [0.20,0.26,0.30,0.40,0.52,0.6] 2 1 [0.83,1.04,1.25,1.65,2.08,2.5]

Table 1: Lathe Machine bridge circuits. Measuring unit: A standard DC motors are B. Dynamometer: provided to measure the output of the bridge unit directions For the measurement of cutting forces a three component in terms of kg. Some instructions are necessary for bridge strain gauge type lathe tool dynamometer is used for the balancing unit before performing the operations. present work. It consists of orthogonal ring and used to measure force values in three directions, one vertical direction two force components in longitude and transverse direction. The assembly consists of four octagonal rings arranged at right angles to each other and strain gauges which are fixed between two thick plates. Range of force measurement is 0-500 kg in all directions. Two rings are used to measure forces in feed direction and the other two in axial direction and all the four rings for the vertical component of cutting force. All the rings are identical in shape and can measure forces in three mutual perpendicular directions The Dynamometer is divided into the following subunits. Sensing unit: the sensing unit consists of four orthogonal rings with strain gauges cemented on arms. The unit accurately senses forces in three axes to the bridge Fig. 2: Sharp Dynamometer (Strain Gauge) circuit. Bridge balancing unit: The bridge balancing unit The sensing unit of dynamometer should be in consists of power supply used to supply power to three proper position on the lathe machine tool post. With help of

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Optimization of Turning Process Parameters for Mild Steel (IJSRD/Vol. 3/Issue 11/2016/021)

cables, carefully connect PUI socket on the sensing unit to the PUI socket on the strain gauge amplifier unit. Similar connections were made for PU2 channel and PU3 channel.

The instrument is made connected to 230 Volts single phase supply. Dynamometer tool holder top view (tool attached).

After all the necessary precautions taken measurement setup was kept ready for the experiment purpose. Align the dynamometer with the lathe machine tool post and clamp it to the T-slots present in the table. Set machine for the automatic feed. Connect the input cable between the socket marked PUI on dynamometer unit and the socket marked PUI on the display unit (bridge balance unit). Similar connections were made for PU2 and PU3 channels. Zero adjustment is being made before taking any reading. Supply the power through main by operating switch and the setup is ready for the measurement of cutting forces on lathe machine. Precautions in force measurement: Following precautions should be taken during the experiment. Socket connections were done very carefully. There should not be any excessive loads on sensing unit. The balance posts are operated carefully. Before taking next reading the bridge should be in balanced condition. After the experiments switch-off the AC mains. The cables were removed properly from socket.

III. WORKPIECE AND TOOL MATERIAL SELECTION The work piece material is Mild steel bar with length of 2 feet and the diameter 50 mm.

Strength of the work piece material is as follows: Mild steel: 550 N/mm2 Tool material is HSS (High Speed Steel).

Mild steel can be machined for turning process with the cutting speeds available on the given lathe machine.

High Speed Steel exhibits a density of 8.67x1000 kg/m3 (kilograms per meters-cubed). This high density affords it incredible durability and hardness (even at high temperatures) and shock and vibration resistance while still allowing for its machinability into tools and drill bits.

A. Tool Grinding: HSS tool bits procured from workshop were ground on the rough grinding machine. The speed of grinding machine was 1500 RPM. The tool geometry as taken from PSG design data book for work piece material as mild steel and tool material HSS are: Back Rake Angle: 110 Side Rake Angle: 110 End Relief Angle: 90 Side Relief Angle: 90 The different approach angles taken on five tools were 700, 750, 800, 850, 900.

Fig. 2: Approach angle 900 and 850.

Fig. 3: Approach angle 800, 750, 700 IV. EXPERIMENTAL OBSERVATIONS Diameter of Mild Steel Bar: 46.5 mm RPM: 250 No. Input Parameters Output Data Depth of App. Feed Fx Fy Cut Angle (mm/rev) (kgf) (kgf) (mm) 1 70 0.05 0.5 17.7 10 2 70 0.05 1 33.3 24.6 3 70 0.05 1.5 44 40.1

Fr (kgf) -1.8 -0.5 1.6

4 5 6 7 8 9

70 70 70 70 70 70

0.05 0.05 0.06 0.06 0.06 0.06

2 2.5 0.5 1 1.5 2

62.8 76.5 20.9 35.7 49 72.1

52 72.4 15.1 29.8 47.4 62.5

4.2 5.9 0.6 2.4 4.9 8.1

10 11 12 13 14 15

70 70 70 70 70 70

0.06 0.07 0.07 0.07 0.07 0.07

2.5 0.5 1 1.5 2 2.5

85.3 19.1 40.9 59 73.3 88.5

74.5 17 37.2 54.3 69.1 84.9

13.2 -0.3 2.1 4.2 8.2 12.4

16 17 18 19 20 21 22

70 70 70 70 70 70 70

0.1 0.1 0.1 0.1 0.1 0.13 0.13

0.5 1 1.5 2 2.5 0.5 1

21.8 46.2 68.2 86 105.9 37 61

22.4 46.8 62.6 66.2 100.4 30.9 58.6

-1.4 1.2 5.4 11.3 16.2 -2.6 1.6

23 24 25 26 27 28

70 70 70 75 75 75

0.13 0.13 0.13 0.05 0.05 0.05

1.5 2 2.5 0.5 1 1.5

83.3 100.2 113.1 14.6 30.4 44.5

82.4 104.3 120.5 7.9 21.3 33.2

5.8 10.2 19.3 0.2 2.2 4.4

29 30 31 32 33

75 75 75 75 75

0.05 0.05 0.06 0.06 0.06

2 2.5 0.5 1 1.5

59.8 66.9 10.8 28.3 44

42.3 58.1 13.5 26.9 42.4

8.7 11.6 1.2 3.4 6.1

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Optimization of Turning Process Parameters for Mild Steel (IJSRD/Vol. 3/Issue 11/2016/021)

34 35

75 75

0.06 0.06

2 2.5

57.6 67.8

53.1 62.3

10.2 13.1

82 83

85 85

0.06 0.06

1 1.5

49.8 62.9

42 53.1

3 10.9

36 37 38 39 40 41

75 75 75 75 75 75

0.07 0.07 0.07 0.07 0.07 0.1

0.5 1 1.5 2 2.5 0.5

24.3 44.3 61.2 71.5 86.1 27.1

12.5 30 45.5 56.8 66.7 16.9

1.8 5.8 8.2 12.7 16.3 -0.4

84 85 86 87 88 89

85 85 85 85 85 85

0.06 0.06 0.07 0.07 0.07 0.07

2 2.5 0.5 1 1.5 2

75.2 87.3 31.1 53.6 68.7 83.9

67.7 82.4 31.2 53.4 70.7 81.9

15.2 23.9 1.6 4.4 8.9 13.8

42 43 44 45 46 47

75 75 75 75 75 75

0.1 0.1 0.1 0.1 0.13 0.13

1 1.5 2 2.5 0.5 1

51.3 70.2 88.9 102.1 25.9 56.8

38.5 58.7 74.3 92.9 19.6 44.6

4.2 8.5 13.4 19.7 0.5 4.6

90 91 92 93 94 95

85 85 85 85 85 85

0.07 0.1 0.1 0.1 0.1 0.1

2.5 0.5 1 1.5 2 2.5

97.3 36.2 64.5 79.8 100.9 111.7

101.1 34.2 63.9 84.3 105.2 125.4

23.7 1.1 6.2 13.4 21.9 22.7

48 49 50 51 52 53

75 75 75 80 80 80

0.13 0.13 0.13 0.05 0.05 0.05

1.5 2 2.5 0.5 1 1.5

80.1 99.1 115.9 22.2 38.4 52.4

67.3 87.3 114.3 16.1 30 42.9

10 15.9 25.1 1.5 3.4 6.4

96 97 98 99 100 101

85 85 85 85 85 90

0.13 0.13 0.13 0.13 0.13 0.05

0.5 1 1.5 2 2.5 0.5

33.7 60.4 86.8 104.7 121.4 31.8

42.5 63.3 98.3 119.3 157.7 23.6

-0.3 5.3 14.8 24.9 39.7 10

54 55 56 57 58 59

80 80 80 80 80 80

0.05 0.05 0.06 0.06 0.06 0.06

2 2.5 0.5 1 1.5 2

65.4 78 21 37.8 53.9 65.3

52 65.2 17.3 32.8 47.5 56.4

8.7 12.9 2.9 5.7 8.3 12.6

102 103 104 105 106 107

90 90 90 90 90 90

0.05 0.05 0.05 0.05 0.06 0.06

1 1.5 2 2.5 0.5 1

54.8 67.2 79.4 87.6 37.8 62.8

35.3 47.6 54.2 68.9 19.6 39.1

16.7 23.8 29.5 27.6 8.9 21.8

60 61 62 63 64 65

80 80 80 80 80 80

0.06 0.07 0.07 0.07 0.07 0.07

2.5 0.5 1 1.5 2 2.5

75.2 21.9 39.2 57.4 69.2 85.9

68.3 19.2 36.4 50.2 63.3 75.2

16.5 -0.6 2.8 6.6 9.4 15.5

108 109 110 111 112 113

90 90 90 90 90 90

0.06 0.06 0.06 0.07 0.07 0.07

1.5 2 2.5 0.5 1 1.5

78.3 93.2 97.1 38.4 54.7 73.8

53.1 60.8 73.4 14.7 31.3 46.4

29.7 36.5 42.6 9.7 16.6 27.3

66 67 68 69 70 71

80 80 80 80 80 80

0.1 0.1 0.1 0.1 0.1 0.13

0.5 1 1.5 2 2.5 0.5

23.8 48.6 66.9 84.8 99.7 28.8

21.1 40.7 57.2 77.6 92.5 24.3

1.6 4.4 7.7 14.9 20.2 -1.8

114 115 116 117 118 119

90 90 90 90 90 90

0.07 0.07 0.1 0.1 0.1 0.1

2 2.5 0.5 1 1.5 2

90.9 102.2 44.5 69.1 91.7 110.9

61.2 74.3 21.1 42.9 62.3 81.8

35.6 43.2 9.1 20.7 30.1 41.3

72 73 74 75 76 77

80 80 80 80 85 85

0.13 0.13 0.13 0.13 0.05 0.05

1 1.5 2 2.5 0.5 1

57.8 77.5 97.9 113.6 35.6 43.8

50.7 65.5 92.2 108.4 19.3 31.6

2.4 5.5 14.3 22.2 -2.9 7.2

120 121 122 123 124 125

90 90 90 90 90 90

54.8 10.8 21.9 35.1 56.6 66.7

78 79 80 81

85 85 85 85

0.05 0.05 0.05 0.06

1.5 2 2.5 0.5

56.7 67.4 77.7 28.3

42.6 54.3 65.7 22.8

11.4 15.8 20.3 1.1

0.1 2.5 119.1 93.3 0.13 0.5 51.9 22.3 0.13 1 83.4 54.3 0.13 1.5 104.7 70.6 0.13 2 124.9 94.6 0.13 2.5 132.1 125.1 Table 2: Experimental Observations

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Optimization of Turning Process Parameters for Mild Steel (IJSRD/Vol. 3/Issue 11/2016/021)

V. GRAPHICAL ANALYSIS AND A. Representations: 1) Force Vs Feed Graphs:

  

Vertical Force x-axis = Feed in mm/rev y-axiz = Force in kgf

Fig. 6: Force vs Feed Graphs Radial Force x-axis = Feed in mm/rev y-axis = Force in kgf   

Fig. 4: Force vs Feed Graphs Horizontal Force x-axis = Feed in mm/rev y- axis = Force in kgf

Fig. 7: Force vs Feed Graphs B. Force Vs Depth of Cut Graphs:   

Feed = 0.13 mm/rev x-axis = DOC in mm y-axis = Force in kgf

Fig. 5: Force vs Feed Graphs

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Optimization of Turning Process Parameters for Mild Steel (IJSRD/Vol. 3/Issue 11/2016/021)

  

Fig. 8: Force Vs Depth of Cut Graphs FEED = 0.10 mm/rev y-axis = Force in kgf x-axis = DOC in mm

Fig. 10: Force Vs Depth of Cut Graphs (Constant Approach Angle)  Vertical Force  x-axis = DOC in mm  y-axiz = Force in kgf

Fig. 9: Force Vs Depth of Cut Graphs VI. FORCE VS DEPTH OF CUT GRAPHS (CONSTANT APPROACH ANGLE)   

Horizontal Force x-axis = DOC in mm y-axiz = Force in kgf

Fig. 11: Force Vs Depth of Cut Graphs (Constant Approach Angle)  Radial Force  x-axis = DOC in mm  y-axiz = Force in kgf

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Optimization of Turning Process Parameters for Mild Steel (IJSRD/Vol. 3/Issue 11/2016/021)

Fig. 12: Force Vs Depth of Cut Graphs (Constant Approach Angle) VII. CONCLUSIONS From the force vs depth of cut graph (at constant angle), it can be seen that force in all the directions increases with the increase in feed. From the force vs depth of cut graph (at constant feed), it can be seen that forces in all directions increases with increase in approach angle. From the force vs feed graphs (at constant approach angle), it can be seen that forces in all directions increase with increase in depth of cut.

Here, Power= Force x Cutting speed It can be stated that the power required for cutting will increase with increase in each of the above three parameters.

REFERENCES [1] Ghosh A. and Mallik A. K., "Manufacturing Science", East West Press, New Delhi, 1998.

[2] Sharma P. C., "A Textbook of Production Engineering", S. Chand & Company, New Delhi, 2006.

[3] http://en.wikipedia.org/wiki/Turning.

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