Optimization of Surface Roughness and Material Removal Rate in Turning of Stainless steel 304.
G. Kalyan Babu*, Pankaj Kumar, R. Chetan
Department of Mechanical Engineering, S R Engineering College, Warangal T.S., India.
*Corresponding Author E-mail: gugulothkalyan45@gmail.com, pikupankaj82@gmail.com
ABSTRACT:
The current study focuses on the turning machining of stainless steel 304 by using different cutting fluids which is ecologically desirable and cost effective. Cutting fluids are popularly used in machining to reduce cutting forces, temperatures and thus prolong the tool life. Vegetable based oil is used as the cutting fluid which is the synthetic fluid which is eco-friendly. The performance of these oils as emulsions for various materials and machining conditions commercialise the cutting fluids in manufacturing industry. The effects of machining parameters on the kinematic viscosity of cutting fluid, material removal rate and surface roughness were investigated during the experimentation. The present study findings should provide the effective solution for economic machining by using the eco-friendly cutting fluid. This approach and results will be helpful for understanding the machinability of AISI 304 stainless steel during turning for the manufacturing engineers.
KEYWORDS: Stainless steel 304 turning, vegetable based cutting fluid, surface roughness measurement.
1. INTRODUCTION:
AISI 304 SS is amongst the difficult to cut material which has poor surface finish and rapid tool wear are common. The work hardening and low thermal conductivity is recognized to be responsible for the poor machinability of 304 SS. Cutting fluid, as a component of machining industry, has been introduced and applied over 100 years. Cutting fluids are used in metal machining for a variety of reasons such as improving tool life, reducing work piece and thermal deformation, improving surface finish and flushing away chips from the cutting zone. Due to the importance of cutting fluids, significant issues have been raised in their application, recycling and disposal. These oils play an important role in enhancing various aspects of machining properties, including corrosion protection, antibacterial protection, lubricity, chemical stability and even emulsibility. Vegetable oils can be classified in to various ways depending upon the source, application etc.., oils can be edible or non-edible in nature. Compared to mineral oils vegetable oils in general possess high flash point, high viscosity index, high lubricity and low evaporative losses.Various researchers have proved the worth of edible vegetable oils viz., coconut oil, palm oil, soya bean oil, canola oil to be used as eco-friendly fluid.
2. LITERATURE REVIEW:
M. Antony Xavior et al.
[1] carried out an experimental investigation to determine the influence of different cutting fluids on tool wear and surface roughness in turning of AISI 304. The investigation results indicated that coconut oil as a cutting fluid performed better than the other two cutting fluids by improving the surface finish and reducing the tool wear.
Ihsan korkut and Ibrahim Ciftic et al.
[2] reported that during turning of AISI 304 stainless steel, tool flank wear decreases with increasing the cutting speed and also surface roughness value increases. It is found that, as feed increases, the radial force increases therefore more friction exists between newly generated surface and the flank face so surface roughness increases.
Ankit Dogra, Hartaj Singh, Vishal Singh, Sunil Kumar et. al.
[3] have analyzed that Taguchi Optimization technique pair with relational analysis has been adopted for evaluating parametric complex to carry out acceptable surface roughness lower is better of the material steel during turning on a lathe trainer
L B Abhang et. al.
[4] focused on parametric investigation of turning process on EN-31 steel, investigated turning process parameters on steel. Experiments have been conducted using factorial design, to study the effect of machining parameters such as cutting speed, feed rate, depth of cut, tool nose radius and lubricant on surface roughness while turning.
Ch. Maheswara Rao et al.
[5] on his paper optimization of surface roughness and studied the effect of cutting parameters (speed, feed and depth of cut) in CNC to achieve low surface roughness using HSS tool.
Shivam Goyal et. al.
[6] investigated experimental study of turning operation and optimization of MRR and surface roughness using Taguchi method. In this research work turning operation is performed on steel. The experiments were performed by taking Cutting Speed, Feed Rate & Depth of cut as process parameters and got the optimized value of MRR.
Zeman A, Sprengel A. et. al.
[7] Cutting fluids may cause irritation or allergy and microbial toxins are generated by bacteria and fungi present, particularly in water-soluble cutting fluids and they are very harmful to the operators.
Li F. Hanson MV, Larrock RC. et. al.
[8] Due to these concerns, new generation environmental and operator friendly cutting fluids of either synthetic or vegetable oil based natural oils are tried out as replacement to petroleum based water soluble cutting fluids. Of these, vegetable oil based cutting fluids have opened new application domain in machining operations.
Sharafadeen KunleKolawale et.
Al [9] Evaluated performances of palm oil and ground nut oil when compared with that of mineral oil based cutting fluid during machining operation of mild steel. It was found that Viscosity of groundnut oil-based sample was lowest and the range was closest even at very high temperature. Low viscosity means high viscosity index and the tendency to be fluidic at high value of working temperature.
S.A.Lawal et.al
[10] carried out a review on the applicability of vegetable oil concluded the best performance when compared to mineral oil on turning of AISI 304 austenitic stainless steel. When vegetable oil was applied to turning of AISI 9310 alloy steel using MQL mode of application, there was remarkable improvement of metal removal rate (MRR). High productivity means that higher feed rate was achieved when vegetable-oil-based metalworking fluid was used.
3. MATERIALS AND METHODS:
· Workpiece material used in the present study is Austenetic stainless steel AISI 304.
· Cutting tool material is made of High speed steel tool for obtaining higher performance in turning.
· Cutting fluid is the vegetable based emulsion made of groundnut based oil and cotton seed oil.
· Turning operation is performed on AISI 304 using geared lathe machine.
· Experimentation is done using cotton seed oil for 9 samples and another 9 samples uses ground nut oil as cutting fluid.
4. EXPERIMENTATION:
The turning operation of AISI 304 uses lathe machine. The work piece is fixed in the machine chuck and is rotated at high speed. The cutting tool (insert) is fed in parallel to the axis of rotation. During this machining process the cutting parameters highly depends upon the work piece, cutting tool material, etc. These are determined by experience or machine catalogue. Surface roughness is a widely used attribute of product quality and in most cases a technical necessity for mechanical products. Achieving the desirable surface quality is of great importance for the functional behaviour of a part.
In machining process various parameters are: Input Parameters: Cutting speed, Feed rate, Depth of cut, Insert radius, Cutting fluid, etc and the Output Parameters: Surface roughness, MRR, Tool wear, Cutting forces, MAZ, etc. Surface roughness measurement achieve desired properties or characteristics: Improved wear resistance; Reduced friction energy losses; Improved mechanical properties, for example, enhanced fatigue life, hardness or toughness; Improved aesthetic appearance, etc.
The surface roughness (Ra) is found to be low at high cutting speed because at higher speed continuous chips without built-up edge was obtained which results in improvement of surface finish. Increase in feed friction between workpiece and tool interface increases, which eventually increases the temperature in the cutting zone. Hence, the shear strength of the material reduces and the material behaves ductile fashion and AISI 304 is sticky in nature, which makes the chips to detach from the workpiece difficult, thereby increasing the surface roughness. In addition, as feed increases, the radial force increases therefore more friction exists between newly generated surface and the flank face so surface roughness increases.
5. RESULTS:
Table 01: Representing the Kinematic viscocity of different cutting fluids on turning SS 304.
|
S.NO. |
Cutting Fluid |
Temperature (0c) |
Kinematic Viscosity (Cst) |
|
1 |
Groundnut oil |
40 |
0.93 |
|
2 |
100 |
0.66 |
|
|
3 |
Cotton seed oil |
40 |
0.91 |
|
4 |
100 |
0.63 |
Table 02: Effect of MRR on SS 304 machined using ground nut oil.
|
S.No. |
Speed (rpm) |
Initial dia (mm) |
Final dia (mm) |
Feed (mm/rev) |
Depth of cut (mm) |
MRR (mm3/min) |
|
1 |
305 |
25 |
24 |
0.19 |
0.5 |
2230.17 |
|
2 |
25 |
23 |
0.11 |
1.0 |
2529.61 |
|
|
3 |
25 |
22 |
0.07 |
1.5 |
2364.32 |
|
|
4 |
500 |
25 |
24 |
0.22 |
0.5 |
4233.29 |
|
5 |
25 |
23 |
0.10 |
1.0 |
3769.91 |
|
|
6 |
25 |
22 |
0.06 |
1.5 |
3323.23 |
|
|
7 |
835 |
25 |
24 |
0.23 |
0.5 |
7390.11 |
|
8 |
25 |
23 |
0.10 |
1.0 |
6295.75 |
|
|
9 |
25 |
22 |
0.07 |
1.5 |
6472.81 |
Table 03: Effect of MRR on SS 304 machined using Cottonseed oil.
|
S.No. |
Speed (rpm) |
Initial dia (mm) |
Final dia (mm) |
Feed (mm/rev) |
Depth of cut (mm) |
MRR (mm3/min) |
|
1 |
305 |
25 |
24 |
0.22 |
0.5 |
2464.09 |
|
2 |
25 |
23 |
0.10 |
1.0 |
2299.43 |
|
|
3 |
25 |
22 |
0.07 |
1.5 |
2364.21 |
|
|
4 |
500 |
25 |
24 |
0.22 |
0.5 |
4233.62 |
|
5 |
25 |
23 |
0.10 |
1.0 |
3769.32 |
|
|
6 |
25 |
22 |
0.07 |
1.5 |
3875.22 |
|
|
7 |
835 |
25 |
24 |
0.19 |
0.5 |
6105.08 |
|
8 |
25 |
23 |
0.09 |
1.0 |
5666.18 |
|
|
9 |
25 |
22 |
0.06 |
1.5 |
5548.07 |
Table 04: Effect of Surface Roughness with ground nut oil based cutting fluid.
|
S.No |
Cutting fluid type |
Speed (rpm) |
Feed (mm/rev) |
Depth of cut (mm) |
Surface roughness (µm) |
|
1 |
Groundnut Oil Fluid |
305 |
0.19 |
0.5 |
1.37 |
|
2 |
0.11 |
1 |
1.83 |
||
|
3 |
0.07 |
1.5 |
1.59 |
||
|
4 |
500 |
0.22 |
0.5 |
3.04 |
|
|
5 |
0.10 |
1 |
2.97 |
||
|
6 |
0.06 |
1.5 |
3.23 |
||
|
7 |
835 |
0.23 |
0.5 |
0.81 |
|
|
8 |
0.10 |
1 |
4.16 |
||
|
9 |
0.07 |
1.5 |
4.45 |
Table 05:Effect of surface roughness with cotton seed oil based cutting fluid
|
S.No |
Cutting fluid type |
Speed (rpm) |
Feed (mm/rev) |
Depth of cut (mm) |
Surface roughness (µm) |
|
1 |
Cotton Seed Oil |
305 |
0.22 |
0.5 |
3.3 |
|
2 |
0.10 |
1 |
4.55 |
||
|
3 |
0.07 |
1.5 |
3.5 |
||
|
4 |
500 |
0.22 |
0.5 |
3.34 |
|
|
5 |
0.10 |
1 |
3.24 |
||
|
6 |
0.07 |
1.5 |
3.36 |
||
|
7 |
835 |
0.19 |
0.5 |
4.18 |
|
|
8 |
0.09 |
1 |
4.25 |
||
|
9 |
0.06 |
1.5 |
4.42 |
6. CONCLUSION:
From the above study we had drawn some conclusions based on the results obtained which are explained below:
· Surface roughness is highly dependent on cutting speed and feed rate while turning.
· Cutting fluid should have high flash, fire point, specific heat, optimum dynamic viscosity and adhesiveness.
· Chips formed are uniform and continuous when using the groundnut cutting fluid resulting in good surface finish.
· Material removal rate for SS 304 mm3/min is obtained for groundnut cutting fluid at speed.
· Material removal rate for SS 304 mm3/min is obtained for cotton seed cutting fluid at speed.
· Kinematic viscosity for both the cutting fluids shows significant differences at low level and also at elevated temperatures.
7. REFERENCES:
1. M. Anthony Xavior, M. Adithan, Determining the influence of cutting fluids on tool wear and surface roughness during turning of AISI 304 austenitic stainless steel, journal of materials processing technology 2 0 9 (2 0 0 9) 900–909
2. Korkut,I., Kasap,I., M. Ciftic, I., Seker,U., 2004.Determination of optimum cutting parameters during machining of stainless steel, Materials and designs 25, p.303.
3. Ankit Dogra et al “Optimization of turning parameters of EN-8 steel cylindrical rods using Taguchi methodology”, Int. journal for research in applied science and engineering technology www.ijraset.com ISSN: 2321-9653 Volume 4 Issue XII, December 2016.
4. L B Abhang and M Hameedullah “Parametric investigation of turning process on en-31 steel” Procedia Materials Science 6 (2014) 1516–1523.
5. Ch. Maheswara Rao and K.Venkatasubbaiah “Optimization of Surface Roughness in CNC Turning Using Taguchi Method and ANOVA” International Journal of Advanced Science and Technology Vol.93, pp.1-14,. 2016.
6. Shivam Goyal, Varanpal Singh Kandra, Prakhar Yadav “Experimental Study Of Turning Operation And Optimization Of MRR And Surface Roughness Using Taguchi Method” International Journal of Innovative Research in Advanced Engineering Vol. 3, 44-50, 2016.
7. Zeman A, Sprengel A, Niedermeier D and Spath M, “Biodegradable lubricants studies on thermo oxidation of metalworking fluids by differential scanning calorimetry (DSC), Thermochim”. Acta268 (1995) 9–15.
8. Li F. Hanson MV, Larrock RC, “Soybean oil–divinylbenzene thermosetting polymers, synthesis, structure, properties and their relationships”, Polymer 42 (2001) 1567–1579.
9. Sharafadeen Kunle Kolawole, Jamiu kolawale odusote “Performance Evaluation of Vegetable OilBased Cutting Fluids in Mild Steel Machining”, Chemistry and Materials Research, ISSN 2224- 3224 (Print) ISSN 2225-0956 (Online), Vol.3 No.9, 2013, page 35-45.
10. S.A. Lawal, I.A. Choudhury, Y. Nukman, “Application of vegetable oil-based metalworking fluids in machining ferrous metals—A review”, International Journal of Machine Tools and Manufacture (2011), doi:10.1016/j.ijmachtools.2011.09.003.
|
Received on 06.12.2018 Accepted on 22.12.2018 ©A&V Publications all right reserved Research J. Engineering and Tech. 2018;9(4): 323-326. DOI: 10.5958/2321-581X.2018.00044.2 |
|