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Procedia Manufacturing 20 (2018) 548–553
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2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
Machinability Investigation of AISI 304 Austenitic Stainless Steels
Machinability Investigation of AISI 304 Austenitic Stainless Steels
using Engineering
Manufacturing Multilayer AlTiN/TiAlN
Society Coated2017,
International Conference Carbide Inserts
MESICInserts
2017, 28-30 June
using Multilayer AlTiN/TiAlN Coated
2017, Vigo (Pontevedra), Spain
Carbide
Atul Kulkarniaa*,Vikas Sargadebb, Chittaranjan Moreaa
Atul Kulkarni *,Vikas Sargade , Chittaranjan More
Costing models forVishwakarma
capacity optimization
Institute inPune,
of Information Technology,
a
Industry
Indai 4.0: Trade-off
Dr. Babasaheb Ambedkar
Vishwakarma Institute ofTechnological
b a
University, Pune,
Information Technology, Lonere, India
Indai
between used capacity
Dr. Babasaheb Ambedkar b
and operational
*atul.kulkarni@viit.ac.in
Technological efficiency
University, Lonere, India
*atul.kulkarni@viit.ac.in

Abstract A. Santana , P. Afonso , A. Zanin , R. Wernke

a a,* b b

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
In the present study, multilayer AlTiN/TiAlN b coating is89809-000
Unochapecó, used forChapecó,
coating SC,
of cemented
Brazil carbide inserts and those are used for
In the present
machining study, multilayer
of AISI304 austenitic AlTiN/TiAlN
steel with highcoating is used
speed. The for coating
cemented of inserts
carbide cementedused,carbide
are fineinserts
grainedandK-Grade
those are used and
(K-20) for
machining
the coating ofis AISI304
done withaustenitic
cathodic steel with high technique
arc deposition speed. The(PVD).
cemented carbide
It has inserts used,
been observed that are
,forfine
the grained
coating K-Grade of 3.8 μm,
thickness (K-20) and
the micro
coatinghardness
is done ofwith cathodic arcwas
AlTiN/TiAlN deposition
found totechnique
be 34 GPa. (PVD). It has been observed that ,for the coating thickness of 3.8 μm,
Abstract
the micro hardness of
In experimentation, AlTiN/TiAlN
turning operationwas found to
is carried beThe
out. 34 GPa.
range of cutting speed was 100 to 340 m/min. Feed was kept in the range
In experimentation,
of 0.08 turning operation
to 0.20 mm/revolution and the is carried
depth of cutout.isThe
keptrange of cutting
constant of 1 mm.speed was 100
Influence ofto 340 m/min.
cutting speed, Feed wastool
feed and keptcoating
in the range
were
Under
of 0.08 to
studied the
on0.20concept
cutting forceofand
mm/revolution "Industry
average 4.0",tool
and the chip
depth ofproduction
cut processes
is kept constant
interface of 1 will
temperature. mm. be pushed
Influence
The interface to be speed,
of cutting
temperature increasingly
feed and
of 938°C interconnected,
wastool coatingatwere
observed 180
studied on cutting
m/min cutting
information speedforce
based on aand
and realaverage
feed 0.16
time chip tool
and,interface
mm/revolution.
basis temperature.
necessarily, much more The interface
efficient.temperature of 938°C
In this context, was observed
capacity at 180
optimization
m/min
goes cutting
The cutting
beyond speed
speed
the andthe
was feed
traditional 0.16
major mm/revolution.
aimfactor responsible
of capacity for chip toolcontributing
maximization, interface temperature variation where profitability
also for organization’s feed was responsible for
and value.
The cutting
cutting force.speed was
Cutting the
force major
and
Indeed, lean management and continuous factor
cutting responsible
speed showed for chip tool
inverse
improvement interface
proportion temperature
with
approaches othervariation
eachsuggest andcapacitywhere
no built up feed was
edges were
optimization responsible
instead for
found. of
cutting force. Cutting force and cutting speed showed inverse proportion with each other and no built up edges were found.
maximization. The study of capacity optimization and costing models is an important research topic that deserves
© 2017The Authors. Published by Elsevier B.V.
contributions from both
© 2018 The Authors. the practical
Published andB.V.
theoretical perspectives. This paper presents and discusses a mathematical
2017The Authors.
Peer-review
© Publishedbyby
under responsibility
Elsevier
ofElsevier B.V. committee of the 2nd International Conference on Materials
the scientific
Peer-review
model for under responsibility
capacity management of thebased
scientific
on committee
different of the 2ndmodels
costing International
(ABC Conference
and TDABC). on Materials Manufacturing
A generic model has andbeen
Peer-review
Manufacturing under
Design Engineering. and responsibility
Design of the
Engineering. scientific committee of the 2nd International Conference on Materials
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
Manufacturing and Design Engineering.
value. The
Keywords: trade-off
Mulilayer capacitycoating,
AlTiN/TiAlN maximization vs operational
AISI 304 Machinability, cuttingefficiency
temperature,isCAE-PVD
highlighted and it is shown that capacity
coatings
optimization might
Keywords: Mulilayer hide operational
AlTiN/TiAlN inefficiency.
coating, AISI 304 Machinability, cutting temperature, CAE-PVD coatings
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
1. Introduction
1. Introduction
2017.
In the last 20 years, titanium nitride coatings have been widely used in many industrial applications. In spite of
Keywords: Cost
In the Models;
last ABC; titanium
20 years, TDABC; Capacity
nitride Management; Idlebeen
coatings have Capacity; Operational
widely used in Efficiency
many industrial applications.
its enhanced performance, titanium nitride shows limited oxidation resistance at temperatures above 500In°Cspite
[1].ofIt
its
hasenhanced performance,
been reported that withtitanium
addition nitride shows limited
of aluminium, oxidation
the oxidation resistance
resistance at temperatures
of the above 500
coatings are greatly °C [1].up
improved It
has been reported
to working that with
temperatures addition
as high of aluminium,
as 900 the oxidation
°C [2-3]. TiAlN coatings resistance
are used inofdry
thecutting
coatings are greatly
operations improved
because up
of their
1.
to Introduction
working temperatures as high as 900 °C [2-3]. TiAlN coatings are used in dry cutting operations
high oxidation [4-5] and good wear resistance [6]. It is commonly used for machining of austenitic stainless steelbecause of their
high
AISI oxidation
304. Since[4-5]
then and good
several wear resistance
research groups have[6].investigated
It is commonly used for machining
the microstructure of austenitic
and property stainlessofsteel
development the
The304.
AISI cost Since
of idlethen
capacity is aresearch
several fundamental
groups information for companies
have investigated and their management
the microstructure of development
and property extreme importance
of the
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789© 2017 The Authors. Published by Elsevier B.V.
in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
2351-9789© 2017 The Authors. Published by Elsevier B.V.
* PauloEngineering.
Design Afonso.
Peer-review underTel.: +351 253 510of
responsibility 761;
thefax: +351 253
scientific 604 741 of the 2nd International Conference on Materials Manufacturing and
committee
E-mail address:
Design Engineering.psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.082
 Atul Kulkarni et al. / Procedia Manufacturing 20 (2018) 548–553 549
2 Author name / Procedia Manufacturing 00 (2017) 000–000

coatings. It has been suggested that with increasing aluminium content in the TiAlN coatings, phase changes occur,
resulting in TiN/TiAlN. To further improve the hardness and the oxidation resistance, multilayer coatings with layer
dimensions on the nano-scale have been utilized. Multilayer coatings have new structural features and improved
mechanical properties responding to specific service requirements. Many researchers have investigated the surface
properties of single layer, multilayer and gradient (Ti, Al)N coatings and found that the TiN/TiAlN multilayer
coating have better properties than TiAlN monolayer coating[5-9]. It can be the better substitute for TiAlN coating
for improving the performance and tool life of the cutting tool with same cost.
AISI 304 austenitic stainless steel is the most widely used grade among the other grades of austenitic stainless
steel. It is consumed in large volumes (72%) among the other grades of stainless steels [10]. It is used for aerospace
components and chemical processing equipment, for food, dairy, and beverage industries, for heat exchangers, and
for milder chemicals. They are generally more difficult to machine than carbon and low alloy steels because of their
high strength, high work hardening tendency and poor thermal conductivity.
Considerable research and development efforts are directed worldwide towards improving the machining
operations to ensure efficient and economic machining of austenitic stainless steels by proper understanding of the
behavior of the exotic material austenitic stainless steels during machining. However, difficulties in machining of
austenitic stainless steels remained unchanged. An effective approach is still not available. Also machining of AISI
304 austenitic stainless steel using TiN/TiAlN coated tool deposited by “Cathodic arc evaporation” technique is not
reported. Considering all the above facts the present work aims to study the influence of different machining
parameters on the machinability characteristics using TiN/TiAlN hard coating deposited with Cathodic arc
evaporation” technique on cemented carbide tools.

2. Experimental Details

The machining tests were performed by TiN/TiAlN coated inserts for continuous turning of 18/8 AISI 304
austenitic stainless steel with chemical composition shown in Table 1. The workpiece specimens were 300 mm long
and 80 mm in diameter. ACE CNC LATHE JOBBER XL was used for conducting the machining trials. The
machining tests were performed as per the recommendations of ISO 3685.

Table 1. Chemical composition of the workpiece materials

Elements C Si Mn P S Cr Mo Ni Al V

% by Wt 0.07 0.59 1.20 0.03 0.02 18.53 0.21 8.75 0.001 0.03

The fine-grained uncoated K20 grade cemented carbide turning inserts (KENNAMETAL Make) were coated
with TiN/TiAlN hard coating obtained from Hrithik Tools Pvt. Ltd, India. Cathodic arc evaporation technique is
used to for deposition of TiN/TiAlN coating on the cutting insert. The ISO designation of insert and tool holder
were CNMG12408 and PCLNR2525M12.

Fig.1. Calo-test Image for Coating Thickness of AlTiN/TiAlN Coating

550 Atul Kulkarni et al. / Procedia Manufacturing 20 (2018) 548–553
Author name / Procedia Manufacturing00 (2017) 000–000 3

The calo-test was used for coating thickness measurement, which is shown in Fig.1. The length of the specimen
was 250 mm and diameter was 90 mm. The cutting temperature at the interface was measured specially developed
work tool thermocouple and calibration setup. Also, forces in the turning were measured using Kistler 9257A three-
component piezoelectric dynamometer. The turning tests were conducted at cutting speeds in the range of 100 to
340 m/min, feed in the range of 0.08 to 0.20 mm/rev keeping depth of cut constant at 1 mm.

2.1 Tool-work thermocouple and calibration set-up

The tool-work thermocouple method was used to determine the thermal e.m.f. signals generated at a hot junction
produced by the top layer of the coating and the workpiece as shown in Fig. 2(b). In this experimental set-up tool
and workpiece contact point acted as the hot junction and the other end of the workpiece and the tool acted as a cold
junction. One wire was connected to the rear end of the workpiece (cold junction) through carbon brush and was
taken to multi-meter. Another wire was screwed to the cutting insert (hot junction) and was connected to multi-
meter. Circuit is completed when tool and workpiece came in contact. In order to avoid the generation of secondary
e.m.f., both tool and workpiece was insulated properly during machining and calibration process.

W/P Insulated
insulated Tool Holder
from chuck

Carbon Multi-Meter
Brush
Fig.2. (a) Calibration Set-up (b) Schematic Experimental Set-up (c) Experimental Set-
up

3. Result and Discussion

3.1 Average chip-tool interface Temperature

Experiments were conducted at cutting speeds in the range of 100 to 340 m/min, feed in the range of 0.08 to
0.20 mm/rev keeping depth of cut constant at 1 mm. For each cutting test thermo-electric e.m.f. was measured. In
order to establish the relationship between the e.m.f. generated and the corresponding temperature, a calibration set-
up was developed as shown in Figs. 2(a) and (c). In this set-up tool-work thermocouple junction was formed using
a AlTiN/TiAlN coated carbide insert and long continuous chip. A heating coil was used for heating the junction
point of coated insert and chip. A standard K-type thermocouple wire was mounted just near the junction point and
connected to temperature indicator. E.M.F. generated between the hot junction and cold junction was monitored by
a digital multi-meter. The linear relationship obtained for the AlTiN/TiAlN coated carbide tool and AISI 304
austenitic stainless steel is shown in Fig. 3. A tool-chip interface temperature model considering the effect of cutting
speed and feed at constant depth of cut (1 mm) was developed based on experimental data. The average interface
temperature results were analyzed using the least error square method using DataFit software. A chip-tool interface
temperature model is expressed as below.

T= 314 * V0.42 * f0.15

where ,
T- Average chip-tool interface temperature (°C), V- Cutting speed (m/min) and F - Feed (mm/rev)
4 Author name / Procedia Manufacturing 00 (2017) 000–000
Atul Kulkarni et al. / Procedia Manufacturing 20 (2018) 548–553 551

630
y = 72.705x + 34.581
530 R² = 0.996

Temperature (oC)
430
330
230
130
30
-70 0 2 4 6 8
Voltage (mV)

Fig.3. Calibration Curve for AlTiN/TiAlN Coated Carbide Insert and AISI 304 Workpiece

The R-squared values of model are 0.99 ,which indicates that the developed model is reliable and could be used
effectively for predicting the average chip-tool interface temperature during turning for the given tool and work
material pair and within the domain of the cutting parameters.
Curves showing the interface temperature by varying one of the input parameters and keeping other parameters
constant are plotted using developed models. Figs. 4(a) and (b) depict the variation of chip-tool interface temperature
with cutting speed, feed at constant depth of cut(1mm), respectively. It can be seen that the interface temperature
increases with increase in cutting parameters and is higher because of poor thermal conductivity of the coating as well
as AISI 304 work material. However, cutting speed has more prominant effect than feed on the chip-tool interface
temperature.

Fig.4. Variation of Interface Temperature with (A) Cutting Speed (B) Feed

3.2 Cutting Force

In turning operation three force components exists viz cutting force, feed force and radial force. The cutting force
acts along the direction of cutting speed (tangential to turned surface). The cutting force plays major role in determining
the machinability of AISI 304 work material. A cutting force model considering the effect of cutting speed and feed
at constant depth of cut (1 mm) was developed based on experimental data. The cutting force results were analyzed
using the least error square method using DataFit software. A cutting force model is expressed as below.
 Author name / Procedia Manufacturing00 (2017) 000–000 5
552 Atul Kulkarni et al. / Procedia Manufacturing 20 (2018) 548–553

Fc=3069 * V-0.089 * f0.91

where ,
Fc- Cutting force (N)
V- Cutting speed (m/min)
f - Feed (mm/rev

The R-squared values of model are 0.98 ,which indicates that the developed model is reliable and could be used
effectively for predicting the cutting force during turning for the given tool and work material pair and within the
domain of the cutting parameters.
Curves showing the cutting force by varying one of the input parameters and keeping other parameters constant
are plotted using developed models. Figs.5 (a) and (b) shows the variation of cutting force with various cutting
speed and feed. It can be seen that cutting force magnitude is higher for low cutting speed and high feed rate, for a
constant depth of cut (1 mm). It is because of the higher coefficient of friction between the tool and the work
material compared to higher cutting speed and lower feed rates. Also, at higher cutting speed and higher feed rates
the temperature generation rate is higher which makes the material soft at cutting zone. This helps in removing the
material at lower cutting forces. However, feed has more prominant effect than cutting speed on the cutting force.

Fig. 5. Effect of (a) cutting speed and (b) feed on cutting force at constant depth of cut of 1 mm

4. Conclusions

Turning experiments on AISI 304 austenitic stainless steel were performed with multi-layered AlTiN/TiAlN coated
carbide tool. The coating was deposited on K-grade insert using Cathodic arc evaporation technique. A chip-tool
interface temperature model was developed considering the effect of cutting speed and feed at constant depth of cut
of 1 mm. The classical tool-work thermocouple method was used to to determine the thermal E.M.F. signals generated
at a hot junction produced by the top layer of the coating and the chip. In order to establish the relationship between
the e.m.f. generated and the corresponding temperature, a calibration set-up was developed. The developed regression
model for interface temperature as well as cutting force shows excellent fit and predicted results are very close to the
experimental results. It also showed that the developed model is reliable and could be used effectively for predicting
the interface temperature and cutting force for the given tool and work material pair and within the domain of the
cutting parameters. Experimental observations indicate that the interface temperature increases with increase in cutting
speed where as feed is the dominant parameter for the cutting force. The interface temperature 938°C was observed at
180 m/min cutting speed and 0.16 mm/rev feed.

Acknowledgements:
 Atul Kulkarni et al. / Procedia Manufacturing 20 (2018) 548–553 553
6 Author name / Procedia Manufacturing 00 (2017) 000–000

The authors gratefully acknowledge the funding support that received from the Department of Science and
Technology, Government of India under DST-FAST TRACK programme for young scientist (sanction No.
SR/FTP/ETA-68/2009 dated 21.04.2010). Also, The authors thanks to the Hrithik Tools Pvt. Ltd., Pune the coating
support.

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