ADAMA SCIENCE AND TECHNOLOGY UNIVERSITY

SCHOOL OF MECHANICAL CHEMICAL AND MATERIALS

ENGINEERING

Department of Mechanical Design and Manufacturing

Engineering
Advanced Machining Technology and Engineering
Individual Assignment-1

Prepared by: - Abreham Dereje

ID No: - PGR/19275/12

Program: -Post Graduate Regular Program

Submitted to Dr. Moera Gutu

Submission date 25/03/2020 .

 Advanced Machining Technology and Engineering (MAE6106) Assignment-1

Question
1. How all Independent parameters affects/influence the Dependent parameters during
Machining?

The independent Variables include: -

 Tool material and coating

 Tool shape and sharpness
 Work piece material and conditions
 Cutting speed, feed, and depth of cut
 Cutting fluids
 Characteristics of the machine tool
 Work holding and fixturing

The dependent Variables include: -

 Types of chip produced

 Force and energy dissipated during cutting
 Temperature rise in the work piece, the tool and the chip
 Tool wear and failure
 Surface finish and surface integrity of the work piece
1.1. Tool material and Coating
1.1.1. Force and energy dissipated during cutting

The cutting temperature is strongly affected by the mechanical properties of the workpiece
material. The higher the tensile strength and hardness of the workpiece material, the greater the
specific cutting energy. Larger forces are required for the chip formation, more work is required
for cutting, more heat is generated, and consequently, higher cutting temperatures are obtained.
Materials having high thermal conductivity κ, specific heat Cp, and larger density ρ allow for
intensive heat to pass onto the chip and workpiece, and, as a consequence, the dissipated energy
is increasing.

1.1.2. Temperature rise in the work piece, the tool and the chip

During machining due to contact between cutting tool and workpiece some energy is dissipated
this dissipated energy during machining is converted to heat, more energy dissipation during
machining is produces more heat is generated during this time if the thermal conductivity of

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workpiece is less than cutting tool which cause more rise in temperature in work-piece, tool
and chip.

1.1.3. Tool wear and failure

Tool materials and coating are mostly having an effect on tool wear. In order to prevent the
tool wear of material coating the tool is advisable if itis coated material there is no chemical
affinity or chemical reaction between the material. but the tool is simply wear if it is uncoated
and of less hard material. Coating of the tool increase tool life by resisting wear of the tool.
Coating Materials Coating Machining efficiency is improved by reducing the machining time
with high speed machining The majority of inserts presently used in various metal cutting
operations are cemented carbide tools coated with a material consisting of nitrides (TiN, CrN,
etc.), carbides (TiC, CrC, W2C, WC/C, etc.), oxides (e.g. alumina) or combinations of these.
Coating cemented carbide with TiC, TiN and Al2O3 dramatically reduces the rate of flank
wear.

1.1.4. Surface finish and surface integrity of the work piece

The selection of proper cutting tool is an important parameter in the machining process of a
part in production. Tool materials must be at least 30 to 50% harder than the work piece
material. Tool materials must have high hot hardness temperature, high toughness, high wear
resistance, high thermal conductivity, and lower coefficient of friction. When cutting ferrous
and hard to machine materials such as steels, cast iron and super alloys, softening temperature
and the chemical stability of the tool material limits the cutting speed. Therefore, it is necessary
for tool materials to possess good high temperature mechanical properties and sufficient
inertness. The machining of hard and chemically reactive materials at higher speeds is
improved by depositing single and multi-layer coatings on conventional tool materials to
combine the beneficial properties of ceramics and traditional tool materials.

Coating Materials Coating Machining efficiency is improved by reducing the machining time
with high speed machining The majority of inserts presently used in various metal cutting
operations are cemented carbide tools coated with a material consisting of nitrides (TiN, CrN,
etc.), carbides (TiC, CrC, W2C, WC/C, etc.), oxides (e.g. alumina) or combinations of these.
Coating cemented carbide with TiC, TiN and Al2O3 dramatically reduces the rate of flank
wear. A primary contributor to the wear resistance of the coating materials is that they are all
much less soluble in steel than WC at metal cutting temperatures. High hardness is beneficial
in resisting the abrasive wear. Retention of hardness even at higher temperatures is very

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important since the tool bit experiences a temperature in the range of 300-1000°C depending
on the machining parameters and the materials to be machined. Micro hardness values of
different coatings measured at different temperatures.

1.2. Tool shape and sharpness

1.2.1. Types of chip produced

Tool nose radius also affects uncut chip geometry, and thus, ratio of uncut chip thickness to
edge radius that may affect the forces in the hard turning process. More interestingly, the
distance from the cutting edge to the nominal machined surface changes across the cutting edge
and is a strong function of tool nose radius.

1.2.2. Force and energy dissipated during cutting

Tool geometry: The cutting geometry is affected by the normal rake angle γ (cutting angle δ),
approach angle χ, nose radius, and shank cross section. heat generation, heat dissipation, and
resulting tool temperature θt that may arise due to the increase of the earlier tool geometric
characteristics.

1.2.3. Temperature rise in the work piece, the tool and the chip

Tool geometry is influence on the temperature during machining. For example, if the rake angle
decrease, cutting tool is highly contact with workpiece so friction at rake face become
increases. Due to this shear angle become decrease and chip become thicker. Thicker chip
implies more energy lost because of shear strain is higher. Then during this time, the
temperature is rise generally the shape of tool one of the factor affecting or cause of temperature
decrease or increase.

1.2.4. Tool wear, surface finish and surface integrity of the work piece

Tool Nose Radius Variations Nose radius is a major factor that affects surface finish of the
machined surface. A larger nose radius produces a smoother surface at lower feed rates and a
higher cutting speed. Large nose radius tools have, along the whole cutting period, slightly
better surface finish than small nose radius tools. study reveals that large tool nose radii only
give finer surface finish, but comparable tool wear with small nose radius tools. Specific cutting
energy slightly increases with tool nose radius. Tool life based on flank wear increases with
increase in nose radius. However, reaches a constant at nose radius greater than 0.4 mm. On
the other hand, tool life based on surface finish shows a local maximum at 0.8 mm nose radius.

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It was suggested that large nose radii result in severe groove wear, and therefore, poor surface
finish. Other than surface finish aspects,

Rake Angle Variation for single point cutting tool most important angle is back rake angle.
The back rake angle affects the ability of the tool to shear the work material and form the chip.
It can be positive or negative. Positive rake angles reduce the cutting forces resulting in smaller
deflections of the workpiece, tool holder, and machine. If the back rake angle is too large, the
strength of the tool is reduced as well as its capacity to conduct heat. In machining hard work
materials, the back rake angle must be small, even negative for carbide, The higher the
hardness, the smaller the back rake angle shall be used. The magnitude of rake angle has
significant effects on the performance of the cutting tool and the surface integrity generated
during machining and negative rake angle tends to generate compressive residual stress
whereas positive rake angle tends to induce tensile residual stress. Further it is suggested that
creating a chamfer on the cutting edge has a similar effect as creating a negative rake angle, by
which the maximum compressive residual stress in the subsurface can be increased. Tool life
is also affected by tool geometry. A tool with a large rake angle becomes weak as a large rake
reduces, the tool cross-section and the amount of metal to absorb the heat.

1.3. Work Piece material and condition

1.3.1. Types of chip produced

During machining by cutting, three types of chips are formed that significantly affect the
surface roughness and the product accuracy. The type of chip formed depends upon the
workpiece material and the machining conditions.

Discontinuous (segmented) chips are produced when brittle materials such as cast iron, bronze,
and some ductile materials (under certain machining conditions) are cut. Brittle materials do
not have the tendency to undergo high shear strains developed in the cutting operation. As the
cutting tool contacts the metal, some compression stresses occur and the chip begins flowing
along the chip–tool interface

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Continuous Chip This type of chip is a continuous ribbon produced when the flow of metal
next to the tool face is not greatly restricted by a BUE or by friction at the chip–tool interface.
Fractures or ruptures do not occur because of the ductile nature of the metal. A continuous chip
is usually formed at high cutting speeds and large rake angles. The continuous chip is
considered ideal for an efficient cutting action because it results in better surface finishes, low
power consumption, and a longer tool life. However, continuous chips are not always desirable,
as they tend to get tangled around the tool holder.

1.3.2. Force and energy dissipated during cutting

Distribution of heat dissipation is true only for carbide tools during cutting speeds exceeding
30 m/min. Again, most of the heat is carried away by the chip. A small amount of the total
generated heat is conducted to the workpiece and the cutting tool. The amount of heat passing
to the tool Qtool affects its hardness, its wear resistance, and its life, while Q wp affects the
dimensional accuracy as well as the machine tool performance.

1.3.3. Temperature rise in the work piece, the tool and the chip

Workpiece materials are either hard material like brittle material or soft material like ductile
for example if we want to cut the hard material this material requires higher power consumption
during machining so at this time more energy is dissipated. This dissipated energy is converted
to heat energy which result in rise in temperature.

1.3.4. Tool wear and failure

Mechanical abrasion wear is highly affected by the workpiece microstructure, hardness,

strength, and work-hardening property. Generally, the higher the hardness of the workpiece
material, the shorter the tool life. The presence of micro hard constituencies also affects the
tool wear. In this regard, for high-carbon steels, the tool life varies considerably with different
pearlitic structures. Spheroidized structures lead to longer tool life than the lamellar structures.
Low-carbon steels containing large percentages of ferrite give longer tool life and large surface

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roughness. A workpiece material having small hard inclusions may appear to have the same
mechanical properties of a less abrasive metal. It requires the same power consumption during
cutting. The machinability of this material would be lower because of its abrasive properties
that are responsible for rapid tool wear. One problem arising from the use of tool life as a
machinability index is its sensitivity to tool material.

1.4. Cutting speed, feed, and depth of cut

1.4.1. Types of chip produced

During machining ductile materials at high cutting speeds and/or high rake angles which
produced continuous types of chips. Deformation takes place along a narrow shear zone called
the (primary shear zone). Continuous chips may develop a secondary shear zone due to high
friction at the tool–chip interface

1.4.2. Force and energy dissipated during cutting

Cutting speed: The cutting forces decrease as the cutting speed increases. Arshinov and
Alekseev (1970) showed that an increase of the cutting speed from 50 to 250 m/min leads to a
21% decrease in the cutting forces. More heat is generated as the cutting speed increases, and
consequently, the maximum temperature on the tool surface increases at higher cutting speeds.
Feed rate: The cutting forces increase with feed rate, as does the amount of heat generated.
Because the chip cross section represents the feed multiplied by depth of cut, the temperature
increases by a smaller degree upon an increase of the feed rate (exponent 0.22) than upon an
increase of the cutting speed (exponent 0.44).

Depth of cut: The total amount of heat generated increases at larger depths of cut because the
main force increases. Additionally, the increase of depth of cut involves a corresponding
increase in the length of active portion of the cutting tool. Such a situation enhances the heat
dissipation through the tool shank, the total amount of heat is increased, and accordingly, the
temperature is slightly higher in a similar way to the effect of tool feed rate (exponent 0.22).

1.4.3. Temperature rise in the work piece, the tool and the chips

The dissipated energy during machining is converted to heat, more energy dissipation during
machining implies that more heat is generated which cause more rise in temperature in work-
piece, tool and chip. This means when we increase cutting speed, deed rate and depth of cut
the temperature also rise with it.

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1.4.4. Tool wear and failure

Increasing cutting speed increases cutting temperature and results in shortening tool life.
Cutting speed varies depending on the type and hardness of the work material. Selecting a tool
grade suitable for the cutting speed is necessary. Increasing cutting speed by 20%decreases
tool life to ½. Has the greatest influence on tool life. As cutting speed increase, temperature
also increase. The heat is more concentrated on the tool than on the work. • The hardness of
the tool changes and relative hardness of the work increases the abrasive action.

1.4.5. Surface finish and surface integrity of the work piece

the relationship between cutting speed and surface roughness is inversely proportional.
Generally surface roughness directly influenced by the spindle speed and the feed rate. It is
observed that the surface roughness increasing with increased feed rate and higher at lower
speed and vice versa for all feed rate. Increasing the cutting speed decrease the. The relationship
between feed rate and surface roughness is proportional. Generally increasing the feed rate
increasing surface roughness. The relationship between depth of cut and surface roughness is
proportional. Generally increasing the depth of cut increasing surface roughness

1.5. Cutting fluid on dependent variables

1.5.1. Types of chip produced

During machining time, we can operate with cutting fluid or in the absence of cutting fluid. If we use
cutting fluid the formation of chis is continuous chip so by using an effective cutting fluid the
Continuous chip with built-up edge is formed. in the absence of cutting fluid formation of
discontinuous and Serrated chip is.

1.5.2. Temperature rise in the work piece, the tool and the chip

Cutting fluid will transfer heat away from the cutting areas and decrease the temperature of
tool and workpiece, particularly at the cutting edge and tool tip. The cooling effect is achieved
through a variety of heat exchange processes, such as conduction, convection, evaporation (or
vaporization), and very little radiation. Cooling effect can reduce chemical reaction, heat
damage, and material adhesion of the tool and extend its life it also inhibits thermal expansion
of machining system, which will reduce thermal deformation of workpiece and improve its
dimension precision.

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1.5.3. Tool wear and failure

Most machining by cutting operations can be performed using cutting fluids. Heat and wear
are produced due to the friction and shearing action that takes place as the chip is formed.
Cutting fluids serve the following functions: Cool the cutting tool and workpiece and lubricate
the cutting too

1.5.4. Surface finish and surface integrity of the work pieces

During the cutting process especially high-speed machining, plastic deformation of the material
near cutting edge is very large, with high temperature and complex mechanical and thermal
stresses. Because of excellent cooling and lubricating properties, cutting fluid (or metalworking
fluid) plays an important role in machining. The main purpose of using cutting fluid is to
decrease cutting temperature, reduce friction between tool and workpiece, extend tool life, and
improve machining efficiency and surface quality. These effects of cutting fluid were obtained
from its chief functions of cooling and lubrication, and additional features of corrosion
protection. In addition to these functions, the physical and chemical interactions between the
surface of the material and cutting fluid during processing will directly affect the quality and
service performances of the machined surface, especially for the precision parts in extremely
harsh environments with long life and high stability requirements According to the principle
of metal cutting, there are three deformation zones during material removal process: shear
deformation zone, contact zone of tool– chip, and contact zone of tool–workpiece. They are
also the areas where the heat generates. Cutting fluid directly affects on these three areas, as
shown in Figure 1. A, B, and C are the main paths where the cutting fluid affects the cutting
area.

Cooling is the most important effect, especially for water-based cutting fluid used in high-
speed machining. During machining process, there is an intense friction at the interface of tool–
chip and tool–workpiece Pure metals are unstable, especially for the fresh machined metal

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surface, and corrosion is a natural trend to change into stable compound, caused by chemical
or electrochemical effect. Generally, oil-based cutting fluids have good corrosion resistance,
which will form a physical barrier on surface to prevent the chemical reaction. But if the cutting
fluid contains organic acids, acidic oxide, or sulfide, chemical corrosion will be caused for
some reactive metals. These fluids are commonly alkaline to prevent metal from corrosion
damage, as well as semi-synthetic fluids. Water-based cutting fluid is an electrolyte solution
and easily cause electrochemical corrosion. Adding suitable anti-corrosion additives can
improve the corrosion resistance of the cutting fluid. These water-soluble antirust agents are
mainly grouped as anode-type, cathode type, and hybrid-type rust preventive.

The performance evaluation of the cutting fluids in machining was mainly based on their effect
on cutting performance (tool life or tool wear, cutting forces, temperature, chip formation, etc.)
and machined surface quality (surface finish, dimensional accuracy, surface hardness, residual
stress, etc.). The effect on cutting performance. According to discussions of the effect of water-
based and oil-based cutting fluids in cutting process of stainless steel, the oil-based cutting
fluids formed solid protective films in the contact areas at low speed, making the adhesion
weaker and preventing the formation of deposits. The cutting fluids affected the friction at low
cutting speeds. When turning copper using CCl4 as a lubricant, chip thickness ratio and friction
coefficient raised from relatively low at 1m/min to approach dry values at 30– 40m/min.
Machining parameters did not vary much with speed in dry conditions, at intermediate speeds,
solid lubricant inclusions in some work materials could build-up, and thermal softening eased
flow at chip–tool contact area at high cutting speeds.

1.6. Characteristics of the machine tool

1.6.1. Types of chip produced

Characteristics of the machine tool is one factors to determine the produced chips if the
machine tool that has vibration & chatter discontinuous chip is formed. If the machine tool
with high mechanical and thermal shock resistance and high toughness continuous chip is
formed.

1.6.2. Temperature rise in the work piece, the tool and the chip

Machine tools with low friction characteristics cause low rise than the machine tools that has
high friction in temperature in work-piece, tool and chip during machining. Because friction
cause rise in temperature.

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1.6.3. Tool wear and failure

Tool wear and failure is minimum if the machine tools have high mechanical and thermal shock
resistance. Tool wear is also minimized if the machine tools are of wear hot hard and ability to
maintain its properties temperature occurring during cutting.

1.6.4. Surface finish and surface integrity of the work piece

To obtain good surface finish and integrity in machining the vibration of machine tool should
be eliminated or reduced. Therefore, for good surface finish and integrity machine tool to be
used are of high mechanical wear resistance, to minimize vibration during machining. Rigidity
of machine tool maintains surface-finish quality.

1.7. Work holding and fixture

1.7.1. Types of chip produced

Work holding device need to be accommodate chip removal. Proper clearances need to be
made to ensure chips do build up, increasing heat in the tool. Chips must also be easy to remove
after machining so that they do not interfere with the alignment of the next workpiece. Continuous chip
is produced by firmly clamping, supporting and supporting the work-piece. But due to vibration of
work-piece during machining discontinuous or serrated chip is produced for when work-piece is lightly
clamped, supported and located.

1.7.2. Force and energy dissipated during cutting

Work holding devices provide fundamental junction, locating and clamping. Locating refers to
orienting and positioning the part relative to the cutting tool. Clamping refers to holding the
part in its proper orientation with enough force to resist the force of cutting but not deform the
part. Clamping force do produce stresses in the part, excess clamping forces can cause
distortion clamping force should be in the direction of cutting forces. Clamping or work holding
device should be designed such that the cutting forces work against the fixed position of the
clamp, not the movable portion. Clamping forces should be as near in alignment with the
cutting force to minimized torsional moment.

1.7.3. Tool wear and failure

If there is no proper clamping is between workpiece and machine tool Wear and failure of the
tool is mostly occurred due to vibration and friction between them. In order to reduce tool wear
There will be properly fix or located the workpiece on the machine during machining. Due to
reducing vibration tool life also will be reduced.

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1.7.4. Surface finish and surface integrity of the work piece

In order to get or obtain good surface finish and integrity during machining time our work-
piece should be clamped, supported and located firmly then avoid improper vibration, which
result in good surface finish and integrity. otherwise if it is there is vibration reduce the quality
of sure finish of the workpiece

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