International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 11 Issue: 01 | Jan 2024
p-ISSN: 2395-0072
www.irjet.net
ANALYSIS OF TOOL WEAR IN TURNING OPERATION OF ALUMINIUM Mr. Nagesh N. Yamul 1, Mr. Gangadhar P. Hulsure 2 1 Lecturer in department of mechanical engineering, S.E.S. Polytechnic, Solapur. 2 Lecturer in department of mechanical engineering, S.E.S. Polytechnic, Solapur
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Abstract - The research focuses on analyzing tool wear
during turning operations on aluminum using High-Speed Steel (HSS) tools. The primary objectives are to determine the specific speed, feed, and depth of cut that minimizes tool wear when working with aluminum parts and HSS tools. Additionally, the study aims to identify the maximum and minimum levels of wear on the HSS tool at different cutting speeds. The experiments involve varying cutting parameters to collect data on tool wear, and the results are analyzed to provide insights into optimizing machining conditions for extended tool life and enhanced efficiency in aluminum turning processes. The research has practical implications for industries seeking to improve tool performance in machining aluminum materials.
The aim of the research is to analyze and understand tool wear during the turning operation of aluminum using HighSpeed Steel (HSS) tools. The overarching goal is to gain insights into optimizing cutting conditions for enhanced efficiency and prolonged tool life
1.2 Objectives 1.
Specific Parameter Identification: Determine specific combinations of cutting parameters, including specific speed, feed rate, and depth of cut, that result in the least tool wear when working with aluminum parts and HSS tools. 2. Wear Analysis at Different Speeds: Investigate and quantify the maximum and minimum levels of wear occurring on HSS tools at various cutting speeds during the turning operation of aluminum. These objectives collectively aim to contribute valuable knowledge for improving the performance and durability of cutting tools in the machining of aluminum components, with potential applications in industries such as automotive, construction, and aerospace.
Key Words: Tool wear, Tool geometry, Aluminium machining, High-stress conditions, High-temperature conditions, Tool failure.
1.INTRODUCTION The turning operation is a fundamental machining process widely employed for shaping various components, with the primary use of a single-point cutting tool. In this context, a diverse range of cutting tools is available, each characterized by distinct geometries and materials tailored to machine different metals and alloys. Aluminium, extensively utilized in automotive, construction, and aerospace industries due to its lightweight and corrosion-resistant properties, is a common material of interest. Cutting tools undergo severe rubbing during metal-to-metal contact with the work piece and chip, operating under high-stress conditions and elevated temperatures. The situation is exacerbated by the presence of extreme stress and temperature gradients near the tool's surface. While cutting tools play a crucial role in removing material to achieve the desired shape, dimensions, and finish during cutting operations, wear inevitably occurs, leading to tool failure. Regular replacement of tools or edges becomes necessary when wear reaches a critical extent to ensure continued and effective cutting action. This research aims to explore the dynamics of tool wear during turning operations on aluminium, focusing on optimizing cutting parameters to mitigate wear and enhance the longevity of cutting tools.
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2. LITERATURE REVIEW Thamizhmanii S. et al. [1] have recovered that the surface roughness from various tests shows a drop-off in value at higher cutting speed and the feed rate. The cutting tool has produced micro chipping and has not impressed the surface finish. Micro cracks were acquired from the border of micro chipping. The notch wear might have been caused due to difficult particles and other impurities existing in the material. There is no placement of built- up- edge that is normally occurring during machining cast iron at lower cutting speed. Advance work can be carried in the way of measuring the residual stresses by turning and placement of built- up edge under high speed machining. Ozel Tugrul et al. [2] have deliberated that tool nose design affects the surface finish and productiveness in the finish hard turning processes. Surface finishing and the tool flank wear have been analyzed in finish turning of AISI D2 steels (60 HRC) using ceramic inserts. Twofold linear regression models and neural network models are formulated for predicting surface roughness and the tool flank wear. In neural network modeling, measured forces, power and specific forces are used in training algorithm. Experimental
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