International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017
p-ISSN: 2395-0072
www.irjet.net
Performance of machining parameters on powder metals by using PCBN tool and carbide tool L. Anwesh kumar 1, Mr.K. Vishwanath 2, Mr.D.Harsha Vardhan 3 1P.G
scholar, Sri Venkateswara Institute Of Technology, Anantapuram
2
Asst.professor Sri Venkateswara Institute Of Technology,Anantapuram
3
Asst.professor Sri Venkateswara Institute Of Technology, Anantapuram
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Abstract - Present work includes understanding the effects of various milling parameters such as spindle speed, feed rate, and depth of cut on the surface roughness (Ra) of finished products. The experimental plan was based on Taguchi’s technique on surface roughness. Powder metals are becoming mostly used metals in the automotive and other manufacturing industries because they are widely using product functional requirements without compromising the performance of the product. They give various advantages, including weight reduction, near net-shape processing capability, and their ability to be sintered to achieve desired properties in the end-product. Machining of powder metals is quite different to machining of traditional metals because of their specific properties, including porosity. The experiments were conducted on powder metal steel material on CNC vertical milling machine using PCBN and carbide tools. The analysis of mean and variance technique is employed to study the significance of each machining parameter on the surface roughness. This experimental work deals with the finish machining of powder metal steels in automotive applications, for increased tool-life/reduced tool-wear. Tool-life is affected by a various factors such as cutting conditions and tool geometry.
Keywords- Powder metals, PCBN tool, carbide inserts, CNC vertical milling machine, tool parameters . 1.INTRODUCTION The theme of this thesis study is to obtain optimum cutting conditions for maximum tool-life in boring and plunge cutting of powder metal steels using PCBN and carbide tools. Powder metals have been around in the market for quite some time now. However, their potential use in the area of automotive manufacturing is beginning to be appreciated lately. With the automotive industries moving toward addressing the sustainability issues involving reduction in energy consumption, pollution reduction, etc., powder metal components offer a highly attractive light weight property with the additional advantage that they can be easily shaped into various complex parts. Powder metals, unlike conventional metals are considered to be ‘difficult to machine’ materials, due to © 2017, IRJET
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their inherent porous properties. From the review of the published literature in the area of powder metal machining, there appears to be lack of fundamental studies in the mechanics and the cutting action of sintered powder metal parts. It has been estimated that about 30% of powder metallurgy structural components made for automotive industries require some form of machining (Holzki, 1996). This high proportion of machining involved with powder metals in the automotive industries and the lack of fundamental knowledge in machining of porous powder metals inspired this thesis work.
MACHINING OF POWDER METALS This chapter reviews the recent and relevant published work in the area of powder metal machining using PCBN and carbide tools. It has been noted that only limited published work exists on machining of powder metals. This chapter covers only a summary of reviews from these papers. The subsequent chapters of this thesis cover reviews of other relevant topics such as modeling of toolwear and machining optimization. The major variables that influence the mach inability of powder metals are: (a) powder metal material and properties, (b)
cutting tool materials,
(c)
cutting conditions,
(d)
cutting tool geometry,
(e)
coolant application and
(f)
Type of machining operation.
In what follows, a brief review of these influencing variables and how they affect machining of powder metals will be presented.
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