Experimental Investigation, Analysis and Optimization of Turning EN 41 Steel

IJSTE - International Journal of Science Technology & Engineering | Volume 3 | Issue 11 | May 2017 ISSN (online): 2349-784X

Experimental Investigation, Analysis and Optimization of Turning EN 41 Steel Vineesh Department of Mechanical Engineering Saranathan College of Engineering

Raja Samuel Department of Mechanical Engineering Saranathan College of Engineering

Abstract This Experimental study mainly focus on the Optimization of the cutting parameters on MRR of EN 41 alloy steel with carbide tool. The input parameters like cutting speed, Depth of Cut (DOC), feed rate and coolant flow rate are influencing in Material Removal Rate (MRR) using Taguchi method. The contribution and significant parameter are determined by using the Taguchi Design of Experiments (DOE) method. A number of turning experiments were conducted using the L9 orthogonal array on a CNC machine. In this paper analysis is based on Taguchi method of optimization and experimental design and further analysis is carried out with the help of statistical software MINITAB-17.

Keywords: Optimization, Carbide Tool, Turning Experiments, Depth of Cut, Material Removal Rate, MINI TAB-17 ________________________________________________________________________________________________________ I.

INTRODUCTION

Machining process form the foundation of the manufacturing industry and are required to shape a work piece by removing unwanted material. Machining process were performed by using variety of cutting tools in order to accurately obtain the product of required dimensions and also good surface finish .The whole machining process which includes many processes such as drilling, milling, grinding, etc. Turning could be defined as one of the most basic metal removal machining process. Machining parameters such as number of passes, depth of cut for each pass, feed rate, cutting speed influence the production cost, tool lives, and machining quality to a great extent. The proper selection of cutting parameters can obtain a minimum cost.

EN41 is a high carbon Alloy steel which have a high degree of hardness with the wear resistance with Toughness and ductility.

It is used industries for different applications. Turning is the one of the most important method for cutting, especially for the finished machined parts. The quality of the surface depends upon the machining parameters such as Spindle speed, Feed Rate, Depth of Cut and also Coolant Flow Rate. Hence, it is significant to achieve a product within the tolerance limit and good increasing MRR. When Maximizing the production are the major criteria’s of the Machining Process, the productivity of the metal cutting operation influences on properties such as wear resistance and fatigue strength. EN41 is very well known in the field of manufacturing. EN-41 steel is selected for machinability studies, because it is widely used in the automotive industry for the production of axle shaft, roller bearings, ball bearings, Crankshaft etc. The experimental parameters chosen are: three different cutting speeds, feed rates and depth of cut. Metal Removal Rate (MRR) were chosen as criteria for performance.

II. LITERATURE REVIEW Manufacturing industries are needed to improve the quality of the product with minimum cost. The most of the components are produced by machining process .So, the machining process are attracted by many researchers.

S.S Acharya et al (2014) reviewed on the dissertation work of an investigation of turning process parameters on hard EN31 material, for optimization of Material Removal Rate, machining time in wet and minimum quantity of lubrication system .The experiments also deals with the relation between chip formation and control variables with chip thickness from which the effect on insert wear quality of product. The design of experiment and optimization of the material removal rate, machining time by using the Response Surface Methodology (RSM) and the Central Composite design method (CCD) for total experimental design work and also its analysis for the optimization of Turning process parameters.

B R Dabhi et al (2016) reported about the tool life. The life of tool can be increased by proper selection of machining parameters, geometry parameters and Process parameters. The Design of Experiments used to investigate the effect of the main turning parameters such as spindle speed, feed rate and Depth of cut for tool life. A tool which is selected as carbide tool and empirical equation is calculated for major parameters. The effect of these parameters on the surface Roughness has to be investigated by using Response Surface Methodology (RSM) .Thus by Analyzing the experimental and theoretically optimization of process parameters has been carried out.

S N Naik et al (2014) presents that the experimental results which were obtained after the selection of cutting parameters to ensure maximum MRR, and also less power consumption on a CNC machine. Taguchi Optimization methodology has been applied to optimize the turning of SS316 material. The Turning parameters such as Cutting speed (rpm), feed rate (mm/rev), Depth of Cut in (mm) are determined. The analysis results shows that Ceramic carbide & CBN tools are significant factor for MRR is depth of

All rights reserved by www.ijste.org

50

Experimental Investigation, Analysis and Optimization of Turning EN 41 Steel (IJSTE/ Volume 3 / Issue 11 / 010)

cut .For surface Roughness, Feed rate is the most important factor .For Consumption of power, the cutting of the tool material is significant factor and for CBN tools.

Amarjit Singh et al(2014) reviews experimental and analytical results of an investigation of the three major process parameters such as cutting speed, feed rate, and depth of cut, that affects the surface finish of the turned parts in a dry turning. A two-level, three-parameter experiment was planned by using design of experiment methodology. The work materials which were selected are Aluminum (AISI 6061), mild steel (AISI 1030), and also alloy steel (AISI 4340).The results which were analyzed by applying three methods—traditional analysis, Pareto ANOVA, and the Taguchi method.

Kamaljit Singh et al (2013) investigated the Material Removal Rate (MRR), and also the micro hardness of OHNS steel by using EDM machine was studied. The input parameters which were taken are peak current, pulse on time, voltage gap and flushing pressure which were used for experimental work. Mean effect plot and S/N ratio graphs were used to optimize the machining parameters of the EDM on OHNS steel by using Taguchi’s method. Surface Roughness were investigated by L9 orthogonal array using the Taguchi’s Design of Experiments .The different cutting parameters of the OHNS and also turning parameters were optimized by using S/N ratio and Analysis of Variance (ANOVA) method.

III. EXPERIMENTAL PROCEDURE The equipment’s used in this work are CNC machine, Stop watch, Digital vernier caliper and weighing machine. Taugchi’s orthogonal array technique is followed. According to Taguchi’s method, L9 orthogonal array is used for conducting the experiments with four control factors cutting speed, Feed Rate, Depth of cut and coolant flow rate .An L9 orthogonal which is the combinations of Nine Experiments which were for conducted the carbide tool material. The chemical composition of Work piece material EN 41B Alloy Steel is in below table 1.

C 0.35-0.45

Table - 1 Chemical composition of En 41B Alloy Steel Mn Si S P Cr Ni 0.60 max 0.10-.45 0.04 0.04 1.50-1.80 0.40 Max

Mo 0.10 -0.25

Turning is carried on a CNC lathe. The cutting parameters namely speed, feed, depth of cut and Coolant Flow Rate need to be determined in this turning operation. The turning operations are accomplished using a carbide cutting tool. Proper selection of Material for cutting parameters and tool can produce Maximum Material Removal Rate (MRR). Hence, design of experiments by Taguchi method on cutting parameters was adopted to study the MRR. The experiment was conducted for dry turning operation of EN 41-B alloy steel with carbide tool. The turning operation is carried for a length of 50mm in a CNC lathe. The four parameters such as spindle speed, Feed rate and depth of cut and Coolant flow Rate are selected and experimental conditions are given in the table below Table - 2 Levels and Ranges of input parameter Level 1 2 3 Spindle speed (Rpm) 800 1000 120 Feed rate (mm/rev) 0.2 0.3 0.4 Depth of cut (mm) 0.5 1 1.5 Coolant flow rate (lit/s) 0.0233 0.0417 0.25

Fig. 1: CNC Lathe SINUMERIK (802D)

IV. RESULTS AND DISCUSSIONS The Signal to Noise (S/N) ratio has been determined. From the evaluation of S/N ratio, the significance of each parameter can be determined and also influencing parameters also identified. The effect of process parameters are identified for turning process. The

All rights reserved by www.ijste.org

51

Experimental Investigation, Analysis and Optimization of Turning EN 41 Steel (IJSTE/ Volume 3 / Issue 11 / 010)

table 4 describes the response table for signal to noise ratio for MRR. The signal which represents desirable value and noise represents undesirable value in Taguchi method .Process parameters with highest S/N ratio which will always give the best quality with minimum variance. The S/N ratio is calculated for each parameter by finding average value of S/N ratio at the corresponding level.

From the table 4, the Feed rate is a influencing parameter (Rank 1) for maximum MRR of EN 41 Steel rods And four levels of signal to noise ratio and their relative speed, Feed, depth of cut and coolant flow rate are taken from the Fig 2. From the table 3, it is understood that maximum Material removal rate is possible when spindle speed, feed, depth of cut and coolant flow rate are maximum. Fig 2 shows the Main effect plot for S/N ratio. The level for a factor with the highest S/N ratio was the optimal level for response measured .From the plot, it is observed that the maximum MRR was at higher S/N value in the response graph. The optimal cutting parameters are 1200 rpm spindle speed, 0.4mm/rev feed rate 0.5mm depth of cut and 0.0233 lit/s coolant flow rate. From S/N ratio graph, it is observed that for MRR, The feed rate has the greatest influence followed by Spindle Speed.

The MRR is calculated by using MRR = (Wb- Wa)/Tm Where, Wb=weight before machining Wa= weight after machining Tm= Time taken for machining Table - 3 Effect of Machining Parameters on MRR Spindle speed Depth of cut Feed Rate Weight before Weight After machining Machining S. No (rpm) (mm) (mm) Machining (g) (g) Time (s) 1 800 0.5 0.2 0.467 0.437 58 2 800 1 0.3 0.468 0.419 59 3 800 1.5 0.4 0.464 0.409 59 4 1000 1 0.2 0.472 0.449 55 5 1000 1.5 0.3 0.466 0.425 53 6 1000 0.5 0.4 0.469 0.410 55 7 1200 1.5 0.2 0.470 0.448 44 8 1200 0.5 0.3 0.463 0.421 44 9 1200 1 0.4 0.465 0.413 43 Table - 4 Response table for Signal to Noise ratio for MRR Level Spindle Speed (rpm) Feed Rate (mm/rev) Depth of cut (mm) Coolant Flow Rate (Lit/s) 1.

-27.19 -30.89 -26.31 -26.59 2.

-27.55 -25.94 -27.03 -26.84 3.

-26.06 -23.97 -27.47 -27.37 Delta 1.49 6.92 1.15 0.78 Rank 2 1 3 4

MRR (g/s) 0.031 0.049 0.055 0.025 0.046 0.064 0.03 0.057 0.072

Fig. 2: Main Effects Plot for S/N Ratios

V. CONCLUSION The following are conclusions drawn based on the experimental investigation conducted on turning EN 41-B alloy steel with carbide cutting tool at four parameters by employing Taguchi technique to determine the optimal level of process parameters. The present work shows the use of Taguchi method to find out the optimal machining parameter .By using Taguchi method, we

All rights reserved by www.ijste.org

52

Experimental Investigation, Analysis and Optimization of Turning EN 41 Steel (IJSTE/ Volume 3 / Issue 11 / 010)

determine the S/N ratio for all experimental tests. Machining Parameters such as Cutting speed, Feed rate, depth of cut and Coolant Flow Rate were optimized to meet the required Objective.  Taguchi’s robust orthogonal array design method is used to analyze the Material Removal Rate.  It is found that Taguchi method is simplified and effective method in the optimizaton for the machining Parameters.  The Experimental Results shows that the major parameters (spindle speed,Feed Rate,Depth of cut and coolant Flow rate) which is considered affects the Material Removal rate (MRR) of a EN 41-B alloy steel material.

REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9] [10]

[11] [12] [13] [14] [15]

S.S Acharya, R.L. Karwande (2014) , “Experimental Investigation of Turning Process in Wet and MQL system on EN 31 Alloy Steel”, International Journal of Scientific & Engineering Research( IJSER) Volume- 6, Issue- 2 , pp.1074-1080.

B.R.Dabhi K. V. Parmar (2016), “Optimization of CNC Face Milling Process Parameters for WC with TiCN Coated Tool Life”, International Journal for Scientific Research & Development (IJSRD), Volume-3, Issue -5, pp. 57-64.

S.N.Naik, J.S. Sidhu , S.S.Kulkarni (2015), “Optimization of cutting Parameters of SS316 using Different cutting Tools on CNC Lathe International Journal of Scientific Research and Management Journal of Scientific & Engineering Research (IJSER),Volume-6, Issue-9, pp.1074-1080.

Amarjit Singh, Rajvir Singh Ghuman (2014), “An Investigation of Surface Finish in Dry Turning”, International Journal of Scientific Research And Education (IJSRE), Volume-2, Issue-5, pp.881-895.

Dr.SP TRIKAL, PRADEEP PATOKAR(2016),”Evaluation of Surface Roughness of Mild Steel Component Turned using Multi Tool Turning Method”,vol.2,pp46-51.

S. Saikumar & M. S. Shunmugam (2012), “Investigations into high-speed rough and finish end-milling of hardened EN24 steel for implementation of control strategies”, The International Journal of Advanced Manufacturing Technology,Volume-63,Issue-1,pp 391–406.

S.R.Das,A.Kumar,D.DhupalandS.K.Mohapatra(2013),” Optimization Of Surface Roughness in Hard Turning of AISI 4340 Steel using Coated Carbide Inserts”,vol.3,pp.871-880.

Kamaljit Singh, C S Kalra (2013), “Machining of OHNS steel by EDM”, Journal of Engineering, Computers & Applied Sciences (JEC& As), Volume-2, Issue-6,pp.39-42.

K Saraswathamma, G Venkateswarlu, S Venkatarami Reddy (2014), “Optimization of surface roughness in the Roller burnishing process using response surface methodology and desirability function”, International conference on Emerging Trends in Mechanical Engineering (ICEME), Volume-9, pp.01-82.

N Muthukrishnan, T T M Kannan, M Robert Sahayadoss , J Madhan , P Vijaya Kumar and R Makesk Kumar (2014), “OPTIMIZATION OF TURNING PARAMETERS OF OHNS (AISI O-1) STEEL RODS USING TAGUCHI METHODOLOGY” , International Journal of Mechanical Engineering and Robotics Research ( IJMERR), Volume-4, Issue.-4, pp.346-352.

Nitin K. Khedkar, T. P. Singh, Vijaykumar S. Jatti (2014), “Material migration and surface improvement of OHNS die steel material by EDM method using tungsten powder-mixed dielectric”, WSEAS TRANSACTIONS on APPLIED and THEORETICAL MECHANICS, Volume-9, pp.161-166.

ASHVIN J.Makadia,J.I.Nanavathi(2013),”Optimisation on maching parameter based on response surface methodology”,vol.46,pp1521-1529.

M. Chandrasekaran,M. Muralidhar,C. Murali Krishna,U. S. Dixit(2010),”Application of soft computing techniques in machining performance prediction and optimization: a literature review”,vol.46,pp445-464 SUHA K SHIHAB, ZAHID A KHAN, AAS MOHAMMAD and ARSHAD NOOR SIDDIQUEE (2014),”optimisation on surface integrity in dry hardening using rsm”,vol.39, pp1035-1053.

Sushil D. Ghodam(2014),” TEMPERATURE MEASUREMENT OF A CUTTING TOOL IN TURNING PROCESS BY USING TOOL WORK THERMOCOUPLE”,vol.3,pp831-835.

All rights reserved by www.ijste.org

53