CHAPTER-1

INTRODUCTION

Hard machining means machining of parts whose hardness is more than

45HRC but actual hard machining process involves hardness of 58HRC to
68HRC.The work piece materials used in hard machining are hardened alloy steel ,
tool steels , case – hardened steels , nitride irons , hard – chrome – coated steels
and heat – treated powder metallurgical parts.

1.1. ADVANTAGES (BENEFITS) OF HARD MACHINING

1. Complex part contours can be easily machined by this process.
2. Component types can be quickly changed over in this process.
3. In one set – up, many operations can be completed.
4. Metal removal rate is very high.
5. The CNC Lathe which is used for soft turning process can be used for this
process.
6. Investment in machine tool is very low.
7. Metal chips produced in the process are environmentally friendly.
8. No coolant is required in many cases.
9. Tool inventory required is small.

1.2. LIMITATIONS (DRAW BACKS) OF HARD MACHINING

1. The cost of tooling in case of hard machining is higher than grinding.
2. For hard turning the length to diameter (L/D) ratio should be small. For
unsupported work pieces it should not be more than 4:1 because long thin
parts will induce chatter due to high cutting pressure.

1
 3. For hard machining to be successful, the machine used must be rigid. The
degree of hard turning accuracy is known from degree of machine rigidity. If
we want to maximize the machine rigidity than we have to minimize
overhangs, tool extensions and to eliminate shims and spacers.
4. The main challenge in hard machining is whether or not to use coolants, in
some cases where there are interrupted cuts such as gears dry machining is
good. Due to shock produced by thermal effect the insert will feel exiting
and entering cut and insert will break. In case of continuous cut due to high
tool tip temperature softens the area which are machined previously and
decreases the value of hardness due to which material is easily cut. But due
to dry machining part thermal distortion, handling and in process gauging is
difficult so if coolant will be used then water based coolants should be used.
5. Surface finish decreases with increase of tool wear in the range of tool life.
6. In hard machining, a very thin layer of material which is harder than inner
material is formed which is known as white layer. With tool wear increase
its thickness increases. White layer is commonly formed on bearing steel
and makes problem for bearing races which receive high contact stresses.
The white layer causes bearing failure.

1.3. FEATURES IN WHICH HARD MACHINING IS DIFFERENT FROM

CONVENTIONAL MACHINING
1. When work material gets fractured chip in the form of saw tooth is formed.
Within the range of shear strain crack is formed at the free surface of the
work piece.

2
 2. Because of adiabatic shear segmental chips are formed in materials which
are difficult to machine and its cross section is similar to saw-toothed chip
formed in hard machining but these two chips are not same because they are
produced due to different mechanisms.
3. 3.The shear angle in case of hard machining is very small and increases with
increase of hardness of work material and do not depend upon tool rake
angle but the shear angle in case of traditional machining is large.
4. Radial (thrust) component of the cutting force is greater than tangential
(power) component cutting force in case of hard machining. The difference
between these two forces increases with increase of flank wear.
5. The tangential (power) component and radial (thrust) component depend
upon the tool rake angle. At zero rake angle the components do not increase
with hardness of material. At tool rake angle -20 degree, these components
reduce with hardness of work material.
6. The chip compression ratio is equal to two in case of hard machining.
7. The radial component and tangential component depend upon flank wear
differently. When flank wear increases from zero to 0.2mm the radial
component increases four fold.

1.4. FACTORS DISTINGUISHING HARD MACHINING

To distinguish between hard machining conventional machining differences
in energy balance should be analyzed. The formula for balance of energy in metal
cutting is given by Pc = Fc.V =Ppd +Pfr +Pjf +Pch
Where Fc = power (tangential) component of the cutting force.
V = cutting speed
Ppd = power consumed due to plastic deformation
Pfr = power used on tool chip interface
3
 Pjf = power used on tool work piece interface
Pch = power used due to formation of new surfaces
The difference in the energy balance in conventional and hard machining of
AISI steel 52100 the following conclusions are made.
1. In hard machining power spent on tool work piece surface is greatest but in
conventional machining it is opposite.
2. Much power is spent in formation of new surfaces in hard machining.
3. Also power spent in the plastic deformation of layer being removed is much.

1.5. HARD TURNING

Hard turning is a process which eliminates the requirements of grinding
operation. A proper hard turning process gives surface finish Ra 0.4 to 0.8
micrometre, roundness about 2-5 micrometre and diameter tolerance +/-3-
7micrometre. Hard turning can be performed by that machine which soft turning is
done. The starting point of hard turning is the material hardness 47 HRC but
regularly hard turning is done on the material having hardness 60HRC and higher.
The materials required for hard turning are tool steel, case-hardened steel, bearing
steel, Inconel, Hastealloy, stellite and other exotic materials are also falling in the
category of hard turning. The length to diameter ratio (L/D) ratio for unsupported
work piece should not be more than 4:1 because though tailstock support is there
for long thin parts chatter would be induced due to high cutting pressure. The
degree of hard turning accuracy is measured by degree of machine rigidity. The
system rigidity is more required for hard turning than machine rigidity. If rigidity
of system is to be maximised then overhangs, extensions of tools, extensions of
parts should be minimised and shims and spacers should eliminated. The purpose
is to keep everything as close to turret or spindle as possible. The main challenge
in hard turning is whether coolant will be used or not.
4
 In maximum cases hard turning will be performed dry. When hard turning
will be performed without coolant, part will be hot. Due to this, it will be difficult
for process gauging. To cool down the machined part coolant is used through the
tool with high pressure. Additional problems are created due to flying cherry red
chips. Mainly water-based and low concentration coolants are used in hard turning.
In hard turning maximum heat is transferred to chip so if chip will be examined
during and after cut then whether the process is well turned or not will be known.
The chips should be glowing orange and flow like ribbon during continuous cut. If
we will crunch the cooled chip and it will disintegrate then it shows that proper
amount of heat is produced.

5
 CHAPTER-2
LITERATURE REVIEW

Dilbag singh and P. Venkateswara Rao [1] investigated how surface roughness
in bearing steel (AISI 52100) is effected by cutting condition and tool geometry. In
this investigation mixed ceramic inserts which are made from Aluminium oxide
and Titanium carbonitride (SNGA) which have different nose radius and different
effective rake angle are used. In this study they concluded that S.R is affected by
feed significantly followed by nose radius and cutting velocity. S.R. is affected
very less by effective rake angle but interaction effect of nose radius and effective
rake angle is significant. RSM is used to develop mathematical model.

Tugrul O zel et all [2] have investigated how surface roughness and resultant
force in hard turning of AISI H13 steel is effected by cutting edge geometry,
hardness of workpiece, feed and cutting speed. In this investigation four factor two
level fractional factorial experiments are used and ANOVA is applied. Hardness of
workpiece, geometry of edge, feed and cutting speed are the four factors. In hard
turning experiment cutting force, feed force, thrust force and surface roughness
were measured. From the study the significant factors on surface roughness are
found to be hardness of workpiece, geometry of cutting edge, feed and cutting
speed. Lower workpiece hardness and honed edge geometry produce better S.R.
Geometry of cutting edge, hardness of workpiece, cutting speed affect force
components.

6
B. Fnides et.al [3] conducted the experiment to determine the statistical model of
surface roughness in hard turning of high alloyed steel X38CrMo5-1. This steel is
hardened to 50HRC and is machined by mixed ceramic tool (insert cc650 of
chemical composition 70% Al2O3 + 30% Tic) free from Tungsten on Cr-Mo-V
basis, intensive to temperature changes and high wear resistance. By 33 full
factorial design total 27 experiments were carried out. The levels low, medium,
and high of the parameters are set. Mathematical models are deduced by multiple
regression method in order to express the influence of each cutting regime element
on surface roughness. Finally the result concludes that feed rate is the main factor
influencing surface roughness followed by cutting speed. Depth of cut has not any
important effect on surface roughness.

Dr. G. Hrinath Gowd et.al [4] studied on Fx, Fy, Fz and S.R. and developed
second order polynomial model for them. Mainly the problems in turning are due
to cutting parameters (Fx, Fy, Fz and S.R.). Experiments were performed and it is
concluded that cutting force, feed force, thrust force and surface roughness are
significantly affected by speed, feed and depth of cut. Prediction of mathematical
models of estimation of Fx, Fy, Fz and S.R, RSM is used.

K. Adarsh kumar et.al [5] investigated how surface finish of EN-8 is affected by
spindle speed, feed and depth of cut. Experimental measurements were determined
multiple regression analysis and ANOVA. Cemented carbide inserts are used to
predict surface roughness by multiple regression analysis. The purpose is to form a
relation between cutting speed, feed and depth of cut to optimize S.R. using
multiple regression analysis.

7
S.B. Salvi et.al [6] studied on hard turning of 20MnCr5 steel. The purpose of this
study is to analyze optimum cutting conditions to get lowest surface roughness in
turning of 20MnCr5 steel. Taguchi method is applied in this process. Orthogonal
array, signal to noise ratio and analysis of variance are applied to investigate the
cutting characteristics. From the experiment it is concluded that feed rate has the
significant role to produce lower surface roughness followed by cutting speed. In
this experiment the cutting insert used is ceramic based TNGA160404.

F.Puh et.al [7] used Taguchi design and optimized the process parameters for hard
turning of AISI 4142 and in this experiment he used PCBN tool. L9 orthogonal
array having three level and four factor, SN ratio and ANOVA are used for this to
study cutting parameters (speed, feed, depth of cut) with consideration of S.R.
Multiple regression analysis was used to find first order linear and second order
prediction model for surface roughness and independent variables.

Ali Riza Motorcu [8] investigated how S.R. in turning of AISI 8660 is affected by
cutting speed, feed, depth of cut and tool nose radius using P.V.D. coated ceramic
cutting tool. He analyzed the process by orthogonal design, SN ratio, ANOVA and
found that feed rate is the effective parameter followed by depth of cut and nose
radius. Cutting speed is not significant. Due to surface hardening effect the
interaction of feed and doc was found to be significant.

R. Ramanujan et.al [9] presented a new methodology for the optimisation of the
machining parameters on turning Al-15% SiCp metal matrix composites.
Desirability function analysis is applied optimize the machining parameters.
Experimental design for the experiment is L27.

8
Multiple performance considerations namely surface roughness and power
consumption is applied for optimization of the machining parameters such as
cutting speed, feed rate and depth of cut. Composite desirability value is used to
find optimum machining parameters.

A.D. bagawade et.al [10] evaluated the area ratio of chip. He also evaluated S.R.
in hard turning of AISI52100 (EN-31) steel. The hardness of steel was about 48-50
HRC and this was machined by PCBN tool. The effect of speed, feed and depth of
cut on chip area ratio and S.R were found.

9
 CHAPTER-3
THEORITICAL STUDY

3.1 SURFACE ROUGHNESS

Due to the increased knowledge and constant improvement of the surface
textures gives the present machine age a great advancement. Due to the demand of
greater strength and bearing loads smoother and harder surfaces are needed. The
surface texture has direct contact with the functioning of machine parts, load
carrying capacity, tool life, fatigue life, bearing corrosion and wear qualities.
Failure due to fatigue always occurs at the sharp corners because of stress
concentration at that place. Sharp corner is the place where any surface irregularity
starts and that part fails earlier. Surface irregularity at non-working surface also
matters for failure. Different requirements demand different types of surfaces so
measurement of surface texture quantitatively is essential. The imperfections on
the surface are in the form of succession of hills and valleys varying both in height
and spacing. Any material being machined by chip removal process cannot be
finished perfectly due to some departures from ideal conditions.
Due to conditions not being ideal the surface being produced will have some
irregularities and these irregularities can be classified into four categories given as
follows
a. First order This type of irregularities are arising due to inaccuracies in the
machine tool itself for example lack of straightness of guide ways on which
tool post is moving. Irregularities produced due to deformation of work
under the action of cutting forces and the weight of the material are also
included in this category.
b. Second order These orders of irregularities are caused due to vibration of
any kind such as chatter marks.
10
 c. Third order If the machine is perfect and completely free of vibrations still
some irregularities are caused by machining due to characteristics of the
process. For example feed mark of cutting tool.
d. Fourth order This type of irregularities are arised due to rupture of the
material during the separation of the chip. Further these irregularities of four
orders can be grouped under two groups. First group includes irregularities
of considerable wave-length of the periodic character resulting from
mechanical disturbances in the generating set up. These errors are termed as
macro-geometrical errors and include irregularities of first and second order.
These errors are also referred to as waviness or secondary texture. Second
group includes irregularities of small wavelength caused by the direct action
of the cutting element on the material or by some other disturbances such as
friction, wear or corrosion. Errors in this group are referred to as roughness
or waviness.

3.1.1TERMS USED IN SURFACE FINISH

i. Roughness: This is produced due to irregular structures in the surface
roughness which is resulted from the inherent action of production process.
ii. Waviness: This is produced due to deflection in work piece or machine
vibrations produced in machine.
iii. Flaws: The irregularities which are produced at one place or infrequently in
widely varying intervals in a surface are called flaws.
iv. Centre line: The line about which roughness is measured.
v. Traversing length: It is the length of the profile necessary for the
evaluation of the surface roughness parameters. The traversing length
includes one or more sampling lengths.

11
vi. Sampling length: It is the length of profile necessary for the evaluation of
the irregularities to be taken into account also known as cut off length.
Mean line of the profile:- It is the line having the form of the geometrical
profile and dividing the effective profile so that within the sampling length
the sum of squares of the distances between effective points and the mean
line is minimum. Centre line of the profile:-It is the line parallel to the
general direction of the profile for which the areas embraced by the profile
above and below the line are equal. Spacing of the irregularities:- It is the
mean distance between the more prominent irregularties of the effective
profile, within the sampling length.

3.1.2 DIFFERENT PARAMETERS USED IN MEASURING SURFACE

ROUGHNESS
i. Arithmetic average roughness: Ra=1/𝐿∫𝑚𝑜𝑑(ℎ)𝑑𝑥𝐿0 over 2-20
consecutive sampling lengths.
ii. Average peak-to-valley height (Rz): This is the average of single peak-to-
valley heights from five adjoining sampling lengths.
iii. Depth of surface smoothness: Rp=1/L∫ (𝐻𝑚𝑎𝑥−𝐻) 𝑑𝑥𝐿0
iv. Levelling depth (Ru): Distance between mean line and a parallel line
through highest peak.
v. Mean depth (Rm): Distance between mean line and a parallel line through
the deepest valley.
vi. Maximum peak-to-valley height (Rmax): Largest single peak-to-valley
heights in five adjoining sampling lengths.
vii. Root mean square roughness: Rq= √1/𝐿∫ℎ2𝐿0𝑑𝑥 14

12
3.1.3METHODS OF MEASURING SURFACE ROUGHNESS:
There are two methods of measuring the finish of machined. They are
a. Surface inspection by co methods
b. Direct instrument measurements
(a) Surface inspection by comparison:
In comparative methods the surface texture is assessed by observation of the
surface. But these methods are not reliable as they can be misleading if comparison
is not made with surfaces produced by same techniques. The various methods
available under comparison method are:
a. Torch inspection
b. Visual inspection
c. Scratch inspection
d. Microscopic inspection
e. Surface photographs
f. Micro-Interferometer
g. Wallace surface dynamometer
h. Reflected light intensity
(b)Direct instrument measurement:
Stylus probe instruments are as follows:- Surface finish of any surface can
be measured by this method. In this type measurement electrical principles are
used and they are stylus probe type instrument. There are two types of these
electrical instruments. Carrier modulating principle is the first type of operation.
The movement of the stylus exploring the surface are caused to high frequency
carrier current.

13
Second type works on voltage generating principle.
a. Profilometer
b. The Tomlinson surface meter
c. The Taylor-Hobson Talysurf
d. Stylus
Out of the above four only Taylor-Hobson Talysurf is used in our experiment
this to calculate surface roughness.

3.2. TOOL WEAR IN TURNING

A constant cutting force is acting in turning operation and turning is a
continuous process. A high temperature is produced at the tool/chip interface
because of constant heat derived from shear deformation energy and friction. The
principal wear factor in turning is high temperature at the tool rake face. The
temperature is around 600 degree for austenitic steels, super alloys or titanium
alloys. Tool wear mechanisms in turning are basically four types in turning. They
are as follows:
a. Crater wear
b. Notch wear
c. Flank wear
d. Adhesion

a. Crater wear: It is a chemical or metallurgical wear. Crater wear is produced

because small particles of the tool rake surface diffuse or adhere on fresh chip.
Scar like shape is produced on the rake face due to mechanical friction and it is
parallel to the major cutting edge. In turning of titanium alloys and low thermal
conductivity materials crater wear is produced.

14
b. Notch wear: It is a combination of flank wear and rake face wear which occurs
just in the point where major cutting edge intersects the work surface. This type
of wear is produced in those materials which have a tendency to surface
hardening due to mechanical loads. When tool passes rub the fresh machined
surface increases hardness of the outer layer. In turning of austenitic stainless
steels and nickel-based alloys notch wear is produced.
c. Flank wear: This type of wear is produced on the flank face of the tool. Wear
land formation is not uniform along major and minor cutting edge of the tool.
This type of wear is produced in case of hard materials because there is not any
chemical affinity between tool and material. The wear mechanism is due to
abrasion in this case.
d. Adhesion: Welding occurs between the fresh surface of the chip and tool rake
face because high pressure and temperature. If materials have metallurgical
affinity the there will be better welding and that will produce a thick adhesion
layer and tearing of the softer rubbing surface at high wear rate. In Aluminium
alloys this type of wear is produced in dry conditions. In hard machining this
type of wear is not produced. Wear curve: The following curve shows mean
flank wear (VB) along time for various cutting speeds.
e. Initial wear region: In this region the sharp new edge worn rapidly. The wear
size VB = 0.05-0.1 mm in this region.
f. Steady wear region: In this region wear rate is constant and increases slowly. In
this zone VB=0.05-0.6 mm onwords.
g. Severe wear region: In this region tool wears in very high rate. When this zone
is reached anew tool must be used in place of worn tool or sharpening must be
done before tool breakage.

15
 Fig: 3.1 Development of flank wear with respect to time

3.3 CUTTING TOOL MATERIALS USED IN CASE OF HARD

MACHINING
During hard machining high temperatures are produced and big mechanical
load is there due to speed so cutting tools must withstand these two things. In some
cases the temperature in the tool/chip interface reaches around 700 degree
centigrade. Severe friction is produced between tool and chip as well as tool and
new machined surface. Keeping in mind the above things the cutting tool materials
should have the following properties:
1. Cutting tool substrate material must be chemically and physically stable at
high temperatures.
2. Material hardness must withstand high temperatures produced at the
chip/tool interface.
3. For abrasion and adhesion mechanisms tool material should have a low wear
ratio.
4. To perform interrupted and intermittent cutting tool material must have
enough toughness to avoid fracture.

16
 Starting from the lowest hardness to the highest hardness the tool materials can
be classified as follows:
1. High speed steel (H.S.S.)
2. Sintered carbide
3. Ceramics
4. Extra hard materials
a. High speed steel: These are of high content carbon steels with a high
proportion of alloying elements such as tungsten, molybdenum, chromium,
vanadium and cobalt. Hardness is about 75 HRC. The T series includes
tungsten, the M series molybdenum. Vanadium produces the hardest
carbides and produces super high speed steels. HSS can withstand
temperature upto 500 degree centigrade.
The HSS produced by power metallurgy process (HSS-PM) possesses a
higher content alloying elements and unique properties like higher toughness,
higher wear resistance, higher hardness and higher hot hardness. Sintered carbide:
Mixing tungsten carbide micro grains with cobalt at high temperature and pressure
sintered carbide tools are produced. These are also known as cemented carbide
tools. Tantalum, Titanium, Vanadium carbides are also mixed in small amount.
Sintered carbides are described by two main factors. One is the ratio of tungsten
carbide and cobalt. Cobalt ranges from 6 to 12% and it acts as binder. Melting
point of Cobalt is 1493 degree centigrade. Cobalt forms a soluble phase with
tungsten carbide grains at 1275 degree centigrade and helps to reduce porosity.
Second is the micro grain size. Micro grain size is smaller than 1 micrometre and
submicrograin are smaller than half micron. The hardness of sintered carbide
increases with the reduction in binder content and tungsten carbide grain size.
Hardness of sintered carbide ranges from 600HV to 1200HV.

17
 Sintered carbides are manufactured in two forms, integral tools and inserts.
Sintered carbides are classified into six groups M, P, K, N, S, H. Each scale
includes a numerical scale for it. In USA C-x scale is used. M, grade includes the
sintered carbides suitable for stainless steel machining. P, includes sintered
carbides for low and medium carbon steels and light alloyed steels. K, includes
sintered carbides for cast irons and alloyed steels. N, is used for Aluminium alloys,
S, for heat resistant alloys and H, for tempered and hardened steels.For each of the
above grades the two digit number 01 to 40 is used, except P, for which 01 to 50 is
used. Lower number indicates harder grades and higher number indicates tougher
grades. In USA C-1 to C-4 are general grades for cast iron, C-5 to C-8 are for steel
alloys, C-9 to C-11 for high wear applications, C-12 to C-14 for impact cases.
The two basic groups of carbides used for machining are tungsten carbide
and Titanium carbide.
a. Tungsten carbide: WC particles are bonded together with cobalt matrix to
give tungsten carbide composite. By powder metallurgy technique WC
particles are bonded together with cobalt in a mixer resulting in cobalt
matrix surrounding WC particles and by this process tungsten carbide tools
are manufactured. WC is frequently compounded with Titanium and
Niobium to impart special properties to the carbide. Steels, Cast irons and
abrasive non-ferrous materials are cut by Tungsten carbide tools.
b) Titanium carbide: Tic has higher wear resistance than WC but it is not as
tough as WC. Nickel-molybdenum alloy is used as matrix. Steels and cast
irons can be machined by TIC.
a. Ceramics: Ceramics can be used for machining the metals at high cutting
speeds and in dry machining conditions because these are very hard and
refractory materials which can withstand up to 1500 degree centigrade
without chemical decomposition.
18
 Ceramic powders are used to mould ceramic materials at pressures 25MPa.
Sintering of ceramic materials is done at 1700 degree centigrade. Ceramic tools
may be of three types for example alumina tools (Al 2O3), Silicon nitride (Si3N4)
and sialon which is combination of Si, Al, O and N. Alumina tools contain mixture
of titanium, magnesium, chromium, or zirconium oxides distributed into alumna
matrix homogenously. Due to this toughness gets improved. Silicon nitride
ceramics have a higher resistance to thermal shock and a higher toughness.
Ceramics have a needle like structure embedded in grain boundary which increases
fracture toughness. These are applied for roughing cast iron under heavily
interrupted cuts. Ceramic tools must be kept hot throughout the operation and
shocks on tool edges at tool entrances exits from the work piece must be avoided.
Extra-hard materials: Extra-hard materials include PCD and PCBN. PCD is used
for machining abrasive non-ferrous metals, plastics and composites. PCBN is used
for machining of hardened tool steels and cast irons.

19
 CHAPTER-4
HARDENING
4.1 METAL HARDENING

The use of this treatment will result in an improvement of the mechanical

properties, as well as an increase in the level of hardness, producing a tougher,
more durable item. Alloys are heated above the critical transformation temperature
for the material and then cooled rapidly enough to cause the soft initial material to
transform to a much harder, stronger structure. Alloys may be air cooled, or cooled
by quenching in oil, water, or another liquid, depending upon the amount of
alloying elements in the material. Hardened materials are usually tempered or
stress relieved to improve their dimensional stability and toughness. Steel parts
often require a heat treatment to obtain improved mechanical properties, such as
increasing increase hardness or strength. The hardening process consists of heating
the components above the critical (normalizing) temperature, holding at this
temperature for one hour per inch of thickness cooling at a rate fast enough to
allow the material to transform to a much harder, stronger structure, and then
tempering. Steel is essentially an alloy of iron and carbon; other steel alloys have
other metal elements in solution. Heating the material above the critical
temperature causes carbon and the other elements to go into solid solution.
Quenching "freezes" the microstructure, inducing stresses. Parts are subsequently
tempered to transform the microstructure, achieve the appropriate hardness and
eliminate the stresses.

20
4.2METAL QUENCHING

Material is heated up to the suitable temperature and then quenched in water

or oil to harden to full hardness according to the kind of steels. Material is heated
to the suitable temperature for hardening, then cooled rapidly by immersing the hot
part is water, oil or another suitable liquid to transform the material to a fully
hardened structure. Parts which are quenched usually must be aged, tempered or
stress relieved to achieve the proper toughness, final hardness and dimensional
stability. Alloys may be air cooled, or cooled by quenching in oil, water, or another
liquid, depending upon the amount of alloying elements in the material and final
mechanical properties to be achieved. Hardened materials are tempered to improve
their dimensional stability and toughness

4.3 VARIOUS STEPS IN QUENCING PROCESS AND IT’S TYPES

The first stage in a quench is known as the vapor stage. Because the
submerged part is so much hotter than the quenchant, a vapor blanket forms around
the part. Cooling of the part occurs during this stage, but it is impeded by the
vapor, which acts as an insulator.
The second stage is the boiling stage, which is characterized by the violent
boiling of the quenchant. Parts cool fastest in this stage because the temperature of
the part has decreased enough during the previous stage for the vapor blanket to
dissipate. With the quenchant able to contact the part unimpeded, it can carry away
the most heat through boiling.
The third stage is the convective stage, during which convection and
conduction further carry heat away from a part. Convection refers to the movement
of a liquid due to the tendency of hotter, less dense liquids to rise while cooler,
denser liquids sink.

21
 Conduction refers to the tendency of heat to dissipate throughout a substance
when there are temperature differences in the liquid. Oils are strongly agitated
during quenches, forcing it to flow upward through a workload. For this reason,
natural convection does not occur.

4.3.1TYPES OF QUENCHING MEDIUM OIL

There are many different types of oil used in quenching, two commonly used
oils are fast and hot oils. Items cooled in fast oils cool more quickly. While cooling
speed in fast oils depends on the specific properties of the oil, the main reason
these oils cool parts more quickly is because they’re formulated to reduce the
length of the vapor stage and extend the length of the boiling stage—the fastest of
the three cooling stages. Parts made of low-carbon steel and low-hardenability
alloys quench better in fast oils.
Quench oils are available with flash points ranging from 270°F to 560°F.
The operating temperature of the oil in an open temperature quench tank should be
at least 150°F below its flash point. When the quench tank is operated under a
protective atmosphere, oil can be used at as high as 50°F below the flash point.

50 QUENCH OIL Low viscosity quench oil that approaches water in quench

speed, yet gives a more uniform, less severe quench than water. Recommended for
open quench system operating below 120°F.

AAA QUENCH OIL The most popular, widely used quench oil. This patented
accelerated quench oil provides a maximum, uniform cooling rate for austenitized
steels, as well as clean, easily washed work when properly maintained.

400 QUENCH OIL Similar to AAA but contains extra reservoir of accelerator

additive for use in situations where excessive consumption occurs.

22
420 QUENCH OIL A “medium hot” oil recommended for accelerated quenching
operations in atmosphere furnaces from 180 to 300°F. Produces uniformly well
hardened parts while holding distortion to a minimum.

MARQUENCH OIL M An accelerated quench oil designed for applications at

250-350°F. The use of this “hot” oil is commonly encountered in carburizing and
carbonitriding furnaces or where parts are prone to distortion and cracking.

VACUUM QUENCH OIL: For use in quenching in integral vacuum furnaces.

Offers excellent quenching rate and thermal stability, good viscosity, and low
volatility.

HIGH SPEED VACUUM QUENCH OIL: Faster quench speed than Vacuum

Quench Oil above, but otherwise very similar
In this project AAA types oil was used for Hardening purpose

4.4 HARDNESS

There are three types of tests used with accuracy by the metals industry; they
are the Brinell hardness test, the Rockwell hardness test, and the Vickers hardness
test. Since the definitions of metallurgic ultimate strength and hardness are rather
similar, it can generally be assumed that a strong metal is also a hard metal. The
way the three of these hardness tests measure a metal's hardness is to determine the
metal's resistance to the penetration of a non-deformable ball or cone. The tests
determine the depth which such a ball or cone will sink into the metal, under a
given load, within a specific period of time. The followings are the most common
hardness test methods used in today`s technology

23
4.4.1 ROCKWELL HARDNESS TEST

i. Rockwell Hardness systems uses a direct readout machine determining the

hardness number based upon the depth of penetration of either a diamond
point or a steel ball. Deep penetration indicated a material having a low
Rockwell Hardness number.
ii. However, a low penetration indicates a material having a high Rockwell
Hardness number. The Rockwell Hardness number is based upon the
difference in the depth to which a penetrator is driven by a definite light or
“minor” load and a definite heavy or “Major” load.
iii. The ball penetrators are chucks that are made to hold 1/16” or 1/8” diameter
hardened steel balls. Also available are ¼” and ½” ball penetrators for the
testing of softer materials.
iv. There are two types of anvils that are used on the Rockwell hardness testers.
The flat faceplate models are used for flat specimens. The “V” type anvils
hold round specimens firmly.
v. Test blocks or calibration blocks are flat steel or brass blocks, which have
been tested and marked with the scale and Rockwell number. They should
be used to check the accuracy and calibration of the tester frequently.

Using the “C” Scale:

a. Use a Diamond indenter

b. Major load: 150 Kg, Minor load: 10 Kg

c. Use for Case hardened steel EN8 steel.

24
BEFORE HEAT TREATMENT

SL.NO TRIAL-1&2&3 AVERAGE HRC

A 16,16,17 16

AFTER HEAT TREATMENT

SL.NO TRIAL-1&2 AVERAGE HRC

A 45,42,46 44
B 46,43,44 44
C 53,49,51 51

4.4.2 COMPARISION OF BEFORE AND AFTER HEAT TRAETMENT

BEFORE AND AFTER TREATED

60

50

40
HARDNESS

30

20

10

0
BEFORE TREAT AFTER TREAT A AFTER TREAT B AFTER TREAT C

25
 CHAPTER-5
MATERIAL AND METHODODLOGY

5.1 WORK PIECE MATERIAL

The work piece is carbon-chrome- alloy which is length is 540(60x9) - mm
and diameter is 32 mm. It is heat treated to make its hardness upto 40, 45&50 HRC
The photograph of work piece material and chemical composition of the carbon-
chrome- alloy.

5.2 WORK MATERIAL DETAILS

Work material – EN8

Work material size–32mm dia Length- 75 mm thickness

5.3 CHEMICAL PROPERTIES

Table 5.1: Chemical properties
TYPICAL CHEMICAL COMPOSITION
C Si CR Mn S
0.36-0.44% 0.10-0.35% 1.00-1.40 0.45-0.70% 0.04%

5.4. CUTTING INSERTS

Cutting inserts used in this experiment are four in number. Each insert has
eight edges so for 9 experiment all eight edges of first three are used and three
edges of last insert is used. The specification of insert is SNMG 120408. The
inserts are Titanium coated carbide inserts

26
APPLICATION
EN8 Material is used in tooling applications requiring a high degree of
accuracy in hardening, such as include taps, gauges, swaging dies, ejector pins, ball
and roller bearings.

27
 CHAPTER-6
EXPERIMENTAL DESIGN

6.1 TAGUCHI DESIGN

Basically, experimental design methods were developed original fisher.
However experimental design methods are too complex and not easy to use.
Furthermore, a large number of experiments have to be carried out when the
number of the process parameters increases, to solve this problem, the Taguchi
method uses a special design of orthogonal arrays to study the entire parameter
space with a small number of experiments only. The experimental results are then
transformed into a signal – to – noise (S/N) ratio to measure the quality
characteristics deviating from the desired values. Usually, there are three
categories of quality characteristics in the analysis of the S/N ratio, i.e., the – lower
– better, the – higher – better, and the – nominal – better. The S/N ratio for each
level of process parameter is compared based on the S/N analysis. Regardless of
the category of the quality characteristic, a greater S/N ratio corresponds to better
quality characteristics.
Therefore, the optimal level of the process parameters is the level with the
greatest S/N ratio Furthermore, a statistically significant with the S/N and ANOVA
analyses, the optimal combination of the process parameters can be predicted.
Finally, a confirmation experiment is conducted to verify the optimal process
parameters obtained from the parameter design. There are 3 Signal-to-Noise ratios
of common interest for optimization of Static Problems. The formulae for signal to
noise ratio are designed so that an experimenter can always select the largest factor
level setting to optimize the quality characteristic of an experiment. Therefore a
method of calculating the Signal-To-Noise ratio we had gone for quality
characteristic.

28
They are
1. Smaller-The-Better,
2. Larger-The-Better,
3. Nominal is Best.

1. SMALLER IS BETTER

The signal-to-noise (S/N) ratio is calculated for each factor level

combination. The formula for the smaller-is-better S/N ratio using base 10 log is:

S/N = -10*log(S (Y2)/n)

Where Y = responses for the given factor level combination and n = number
of responses in the factor level combination.

2. LARGER IS BETTER

The signal-to-noise (S/N) ratio is calculated for each factor level

combination. The formula for the larger-is-better S/N ratio using base 10 log is:

S/N = -10*log(S (1/Y2)/n)

Where Y = responses for the given factor level combination and n = number
of responses in the factor level combination.

3. NOMINAL IS BEST
The signal-to-noise (S/N) ratio is calculated for each factor level
combination. The formula for the nominal-is-best I S/N ratio using base 10 log is:
S/N = -10*log (s2)
Where s = standard deviation of the factor level combination.

29
6.2 DESIGN OF EXPERIMENT

Table: 6.1 Process parameters and their levels

PROCESS PARAMETERS
SPINDLE SPEED
LEVEL
S FEED (mm/Rev) DOC
(N) (RPM)

1 1500 0.10 0.1

2 1750 0.15 0.2

3 2000 0.20 0.3

6.3 MINITAB-17 SOFTWARE

By using Minitab-17 software have optimized the drilling parameters

Fig: 6.1 Mminitab-17 software

30
 Fig:6.2 L9 Array formation

6.4 EXPERIMENTAL ARRANGEMENT AND PROCESS PARAMETERS

LEVELS

 Machine Tool: Batliboi smarturn CNC lathe.

 Work specimen material: EN8
 Size of material: Φ32mm X 60 mm.
 Tool material: Carbide-TAEGUTEC-TT-5100-04 inserts.
 Environment: Coolant not used.
 Metal removal rate calculation: Through weight.
 Machining time measurement: From CNC machine.

31
 Fig :6.3 CNC Machine

6.5. PROCESS PARAMETERS AND VARIABLES

Table 6.2 process parameters and variables

SPINDLE SPEED FEED

S.NO DOC
(N) (RPM) (mm/Rev)
1 1500 0.10 0.1
2 1500 0.15 0.2
3 1500 0.20 0.3
4 1750 0.10 0.2
5 1750 0.15 0.3
6 1750 0.20 0.1
7 2000 0.10 0.3
8 2000 0.15 0.1
9 2000 0.20 0.2

32
6.6 PROJECT METHODOLOGY

The proposed work approach and methodology has been elaborately shown in the

START

THROUGH HARDENING PROCESS

TAGUCHI DESIGN
CHAPTER-5

SELECT PARAMETER CRYO

PROCESSING OF TOOLS

RUN THE EXPERIMENTS

DATA COLLECTION AND ANALYSIS

OPTIMIZATION

RESULT AND CONCLUSION

Fig: 6.4 Project methodology

33
 CHAPTER-7

EXPERIMENTAL DATA

7.1 EXPERIMENTAL DATA ANALYSIS AND OPTIMIZATION

SPEED
FEED MT RA MRR
SL.NO DESIGN (N) DOC
(mm/Rev) SEC micron gm/Sec
(RPM)

1 A1B1C1 1500 0.10 0.1 21 0.645 0.140

2 A1B2C2 1500 0.15 0.2 14 0.574 0.201

3 A1B3C3 1500 0.20 0.3 11 0.803 0.350

4 A2B1C2 1750 0.10 0.2 18 0.921 0.157

5 A2B2C3 1750 0.15 0.3 12 1.090 0.342

6 A2B3C1 1750 0.20 0.1 9 1.364 0.185

7 A3B1C3 2000 0.10 0.3 16 0.927 0.184

8 A3B2C1 2000 0.15 0.1 11 0.784 1.026

9 A3B3C2 2000 0.20 0.2 8 0.656 0.385

Table 7.1 Experimental data analysis

34
7.2 MACHINING TIME (ANALYSIS OF RESULT)

Table: 7.2 Machining Time and S/N Ratios Values For the Experiments
TRIAL DESIGN SPEED FEED DOC MT SNRA1
1 A1B1C1 1500 0.10 0.1 21 -26.4444
2 A1B2C2 1500 0.15 0.2 14 -22.9226
3 A1B3C3 1500 0.20 0.3 11 -20.8279
4 A2B1C2 1750 0.10 0.2 18 -25.1055
5 A2B2C3 1750 0.15 0.3 12 -21.5836
6 A2B3C1 1750 0.20 0.1 9 -19.0849
7 A3B1C3 2000 0.10 0.3 16 -24.0824
8 A3B2C1 2000 0.15 0.1 11 -20.8279
9 A3B3C2 2000 0.20 0.2 8 -18.0618

7.2.1 MT RESPONSE FOR EACH LEVEL OF THE PROCESS

PARAMETER
Table: 7.3 Response Table for Signal to Noise Ratios-Smaller is better
LEVEL SPEED FEED DOC
1 -23.40 -25.21 -22.12

2 -21.92 -21.78 -22.03

3 -20.99 -19.32 -22.16

DELTA 2.41 5.89 0.13

RANK 2 1 3

35
Table: 7.4 Response Table for Means
LEVEL SPEED FEED DOC
1 15.333 18.333 13.667
2 13.000 12.333 13.333
3 11.667 9.333 13.000
Delta 3.667 9.000 0.667
rank 2 1 3

Table: 7.5 General Linear Models: MT versus SPEED, FEED And DOC
FACTOR TYPE LEVELS VALUES
SPEED fixed 3 1500,1750,2000

FEED fixed 3 0.10,0.15,0.20

DOC fixed 3 0.1,0.2,0.3

Table: 7.6 Analysis of Variance for MT, using Adjusted SS for Tests
SOURC %OF
DF SEQ SS ADJ MS F P
E CONTRIBUTION
Speed 2 20.667 10.3333 31.00 0.031 14

Feed 2 126.000 63.0000 189.00 0.005 85

Doc 2 0.667 0.3333 1.00 0.500 0

Error 2 0.667 0.3333 1

Total 8 148.000 100

Regression Equation

MT = 13.333 + 2.000 SPEED_1500 - 0.333 SPEED_1750 - 1.667 SPEED_2000 + 5.000 FEED_0.10

- 1.000 FEED_0.15 - 4.000 FEED_0.20 + 0.333 DOC_0.1 - 0.000 DOC_0.2
- 0.333 DOC_0.3

36
7.2.2 S.N RATIO GRAPHS FOR MACHINING TIMING

Main Effects Plot for SN ratios

Data Means
SPEED FEED DOC
-19

-20
Mean of SN ratios

-21

-22

-23

-24

-25

-26
1500 1750 2000 0.10 0.15 0.20 0.1 0.2 0.3

Signal-to-noise: Smaller is better

Fig: 7.1 Graph for SN ratio

Main Effects Plot for Means

Data Means
SPEED FEED DOC

18

16
Mean of Means

14

12

10

1500 1750 2000 0.10 0.15 0.20 0.1 0.2 0.3

Fig: 7.2 Graphs for means

37
————— 26-Mar-21 5:44:15 PM ————————————————————

Welcome to Minitab, press F1 for help.

Taguchi Analysis: MT versus SPEED, FEED, DOC

Response Table for Signal to Noise Ratios

Smaller is better

Level SPEED FEED DOC

1 -23.40 -25.21 -22.12
2 -21.92 -21.78 -22.03
3 -20.99 -19.32 -22.16
Delta 2.41 5.89 0.13
Rank 2 1 3

Response Table for Means

Level SPEED FEED DOC

1 15.333 18.333 13.667
2 13.000 12.333 13.333
3 11.667 9.333 13.000
Delta 3.667 9.000 0.667
Rank 2 1 3

General Linear Model: MT versus SPEED, FEED, DOC

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

SPEED Fixed 3 1500, 1750, 2000
FEED Fixed 3 0.10, 0.15, 0.20
DOC Fixed 3 0.1, 0.2, 0.3

Analysis of Variance

Source DF Adj SS Adj MS F-Value P-Value

SPEED 2 20.667 10.3333 31.00 0.031
FEED 2 126.000 63.0000 189.00 0.005
DOC 2 0.667 0.3333 1.00 0.500
Error 2 0.667 0.3333
Total 8 148.000

Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.577350 99.55% 98.20% 90.88%

38
Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 13.333 0.192 69.28 0.000
SPEED
1500 2.000 0.272 7.35 0.018 1.33
1750 -0.333 0.272 -1.22 0.345 1.33
FEED
0.10 5.000 0.272 18.37 0.003 1.33
0.15 -1.000 0.272 -3.67 0.067 1.33
DOC
0.1 0.333 0.272 1.22 0.345 1.33
0.2 -0.000 0.272 -0.00 1.000 1.33

7.3 SURFACE ROUGHNESSES (ANALYSIS OF RESULT)

Table: 7.7 surface Roughness and S/N Ratios Values for the Experiments

TRIAL DESIGN SPEED FEED DOC RA SNRA1

1 A1B1C1 1500 0.10 0.1 0.645 3.80881
2 A1B2C2 1500 0.15 0.2 0.574 4.82176
3 A1B3C3 1500 0.20 0.3 0.803 1.90569
4 A2B1C2 1750 0.10 0.2 0.921 0.71481
5 A2B2C3 1750 0.15 0.3 1.090 -0.74853
6 A2B3C1 1750 0.20 0.1 1.364 -2.69629
7 A3B1C3 2000 0.10 0.3 0.927 0.65841
8 A3B2C1 2000 0.15 0.1 0.784 2.11368
9 A3B3C2 2000 0.20 0.2 0.656 3.66192

39
7.3.1 RA RESPONSE FOR EACH LEVEL OF THE PROCESS
PARAMETER

Table: 7.8 Response Table for Signal to Noise Ratios-Smaller is better

LEVEL SPEED FEED DOC

1 3.5121 1.7273 1.0754
2 -0.9100 2.0623 3.0662
3 2.1447 0.9571 0.6052
DELTA 4.4221 1.1052 2.4610
RANK 1 3 2

Table: 7.9 Response Table for Means

LEVEL SPEED FEED DOC
1 0.6740 0.8310 0.9310
2 1.1250 0.8160 0.7170
3 0.7890 0.9410 0.9400
Delta 0.4510 0.1250 0.2230
rank 1 3 2

Table: 7.10 General Linear Models: RA versus SPEED, FEED, DOC

FACTOR TYPE LEVELS VALUES
SPEED fixed 3 1500,1750,2000

FEED fixed 3 0.10,0.15,0.20

DOC fixed 3 0.1,0.2,0.3

40
Table: 7.11Analysis of Variance for RA, using Adjusted SS for Tests
SOURC % OF
DF SEQ SS ADJ MS F P
E CONTRIBUTION
Speed 2 0.32952 0.16476 8.11 0.110 67
Feed 2 0.02795 0.01398 0.69 0.593 6
Doc 2 0.09561 0.04780 2.35 0.298 19
Error 2 0.04065 0.02032 8
Total 8 0.49372 100

Regression Equation

RA = 0.8627 - 0.1887 SPEED_1500 + 0.2623 SPEED_1750 - 0.0737 SPEED_2000

- 0.0317 FEED_0.10
- 0.0467 FEED_0.15 + 0.0783 FEED_0.20 + 0.0683 DOC_0.1 - 0.1457 DOC_0.2
+ 0.0773 DOC_0.3

7.3.2 S.N RATIO GRAPHS FOR SURFACE ROUGHNESS

Main Effects Plot for SN ratios

Data Means
SPEED FEED DOC
4

3
Mean of SN ratios

-1
1500 1750 2000 0.10 0.15 0.20 0.1 0.2 0.3

Signal-to-noise: Smaller is better

Fig: 7.3 Graph for SN ratio

41
 Main Effects Plot for Means
Data Means
SPEED FEED DOC

1.1

1.0
Mean of Means

0.9

0.8

0.7

1500 1750 2000 0.10 0.15 0.20 0.1 0.2 0.3

Fig: 7.4 Graphs for means

————— 26-Mar-21 5:53:59 PM ————————————————————

Welcome to Minitab, press F1 for help.

Taguchi Analysis: RA versus SPEED, FEED, DOC

Response Table for Signal to Noise Ratios

Smaller is better

Level SPEED FEED DOC

1 3.5121 1.7273 1.0754
2 - 2.0623 3.0662
0.9100
3 2.1447 0.9571 0.6052
Delta 4.4221 1.1052 2.4610
Rank 1 3 2

Response Table for Means

Level SPEED FEED DOC

1 0.6740 0.8310 0.9310
2 1.1250 0.8160 0.7170
3 0.7890 0.9410 0.9400
Delta 0.4510 0.1250 0.2230

42
Rank 1 3 2

General Linear Model: RA versus SPEED, FEED, DOC

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

SPEED Fixed 3 1500, 1750, 2000
FEED Fixed 3 0.10, 0.15, 0.20
DOC Fixed 3 0.1, 0.2, 0.3

Analysis of Variance

Source DF Adj SS Adj MS F-Value P-Value

SPEED 2 0.32952 0.16476 8.11 0.110
FEED 2 0.02795 0.01398 0.69 0.593
DOC 2 0.09561 0.04780 2.35 0.298
Error 2 0.04065 0.02032
Total 8 0.49372

Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.142559 91.77% 67.07% 0.00%

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 0.8627 0.0475 18.15 0.003
SPEED
1500 -0.1887 0.0672 -2.81 0.107 1.33
1750 0.2623 0.0672 3.90 0.060 1.33
FEED
0.10 -0.0317 0.0672 -0.47 0.684 1.33
0.15 -0.0467 0.0672 -0.69 0.559 1.33
DOC
0.1 0.0683 0.0672 1.02 0.416 1.33
0.2 -0.1457 0.0672 -2.17 0.162 1.33

43
7.4 MRR (ANALYSIS OF RESULT)

Table: 7.12 MRR AND S/N RATIOS Values for the Experiments
TRIAL DESIGN SPEED FEED DOC MRR SNRA1
1 A1B1C1 1500 0.10 0.1 0.140 -17.0774

2 A1B2C2 1500 0.15 0.2 0.201 -13.9361

3 A1B3C3 1500 0.20 0.3 0.350 -9.1186

4 A2B1C2 1750 0.10 0.2 0.157 -16.0820

5 A2B2C3 1750 0.15 0.3 0.342 -9.3195

6 A2B3C1 1750 0.20 0.1 0.185 -14.6566

7 A3B1C3 2000 0.10 0.3 0.184 -14.7036

8 A3B2C1 2000 0.15 0.1 1.026 0.2229

9 A3B3C2 2000 0.20 0.2 0.385 -8.2908

MRR FORMULA: Before weight-After weight/Time taken X Density

DENSITY-7.85/gmcc
B.Weight 482 484 508 496 488 478 487 485 498

A. Weight 459 462 478 474 456 465 464 453 474

44
7.4.1 MRR RESPONSE FOR EACH LEVEL OF THE PROCESS
PARAMETER
Table: 7.13 Response Table for Signal to Noise Ratios-Smaller is better
LEVEL SPEED FEED DOC
1 -13.377 -15.954 -10.504
2 -13.353 -7.678 -12.770
3 -7.590 -10.689 -11.047
DELTA 5.787 8.277 2.266
RANK 2 1 3

Table: 7.14 Response Table for Means

LEVEL SPEED FEED DOC
1 0.2303 0.1603 0.4503
2 0.2280 0.5230 0.2477
3 0.5317 0.3067 0.2920
Delta 0.3037 0.3627 0.2027
rank 2 1 3

Table: 7.15 General Linear Models: MRR versus SPEED, FEED and DOC
FACTOR TYPE LEVELS VALUES
SPEED fixed 3 1500,1750,2000

FEED fixed 3 0.10,0.15,0.20

DOC fixed 3 0.1,0.2,0.3

45
Table: 7.16 Analysis of Variance for MRR, using Adjusted SS for Tests
SOURC %OF
DF SEQ SS ADJ MS F P
E CONTRIBUTION
Speed 2 0.18302 0.09151 1.13 0.470 30
FEED 2 0.19974 0.09987 1.23 0.448 33
Doc 2 0.06811 0.03405 0.42 0.704 11
Error 2 0.16213 0.08106 26
Total 8 0.61300 100

Regression Equation

MRR = 0.3300 - 0.100 SPEED_1500 - 0.102 SPEED_1750 + 0.202 SPEED_2000

- 0.170 FEED_0.10
+ 0.193 FEED_0.15 - 0.023 FEED_0.20 + 0.120 DOC_0.1 - 0.082 DOC_0.2
- 0.038 DOC_0.3

7.4.2 S.N RATIO GRAPHS FOR MATERIAL REMOVAL RATE

Main Effects Plot for SN ratios

Data Means
SPEED FEED DOC
-7

-8

-9
Mean of SN ratios

-10

-11

-12

-13

-14

-15

-16

1500 1750 2000 0.10 0.15 0.20 0.1 0.2 0.3

Signal-to-noise: Larger is better

Fig: 7.5 Graph for SN ratio

46
 Main Effects Plot for Means
Data Means
SPEED FEED DOC
0.55

0.50

0.45
Mean of Means

0.40

0.35

0.30

0.25

0.20

0.15
1500 1750 2000 0.10 0.15 0.20 0.1 0.2 0.3

Fig: 7.6 Graphs for means

————— 28-Mar-21 5:57:50 PM ————————————————————

Welcome to Minitab, press F1 for help.

Taguchi Analysis: MRR versus SPEED, FEED, DOC

Response Table for Signal to Noise Ratios

Larger is better

Level SPEED FEED DOC

1 -13.377 -15.954 -10.504
2 -13.353 -7.678 -12.770
3 -7.590 -10.689 -11.047
Delta 5.787 8.277 2.266
Rank 2 1 3

Response Table for Means

Level SPEED FEED DOC

1 0.2303 0.1603 0.4503
2 0.2280 0.5230 0.2477
3 0.5317 0.3067 0.2920
Delta 0.3037 0.3627 0.2027
Rank 2 1 3

47
General Linear Model: MRR versus SPEED, FEED, DOC

Method

Factor coding (-1, 0, +1)

Factor Information

Factor Type Levels Values

SPEED Fixed 3 1500, 1750, 2000
FEED Fixed 3 0.10, 0.15, 0.20
DOC Fixed 3 0.1, 0.2, 0.3

Analysis of Variance

Source DF Adj SS Adj MS F-Value P-Value

SPEED 2 0.18302 0.09151 1.13 0.470
FEED 2 0.19974 0.09987 1.23 0.448
DOC 2 0.06811 0.03405 0.42 0.704
Error 2 0.16213 0.08106
Total 8 0.61300

Model Summary

S R-sq R-sq(adj) R-sq(pred)

0.284716 73.55% 0.00% 0.00%

Coefficients

Term Coef SE Coef T-Value P-Value VIF

Constant 0.3300 0.0949 3.48 0.074
SPEED
1500 -0.100 0.134 -0.74 0.535 1.33
1750 -0.102 0.134 -0.76 0.527 1.33
FEED
0.10 -0.170 0.134 -1.26 0.334 1.33
0.15 0.193 0.134 1.44 0.287 1.33
DOC
0.1 0.120 0.134 0.90 0.465 1.33
0.2 -0.082 0.134 -0.61 0.602 1.33

48
 CHAPTER-8
RESULT & CONCLUSION

In this study, the Taguchi technique and ANOVA were used to obtain
optimal Turning parameters in the Turning of EN8 under Dry conditions.

The present study investigates extensively on the aspects related to surface

roughness, parametric optimization and Taguchi analysis in hard turning using
coated carbide inserts. Based on the investigations, following conclusions may be
drawn.
1. Good surface quality of roughness about 0.574 micron is obtained during
hard turning operation.
2. The Minimum surface finish was obtained when depth of cut of 0.2mm,
Spindle speed of 1500 RPM and feed 0.15 mm.
8.1 OPTIMAL CONTROL FACTOR

1. Surface Roughness-A1 (Speed - 1500) B3 (Feed – 0.20) C2 (DOC –0.2)

2. Machining Timing- A2 (Speed - 1750) B1 (Feed – 0.10) C3 (DOC – 0.3)
3. Material Removal Rate- A2 (Speed - 1750) B1 (Feed – 0.10) C3 (DOC – 0.3)

8.1.1 Percentage of contribution of Process parameter

1. Surface Roughness- Speed- 67%

2. Machining Timing- feed- 61%
3. Material Removal Rate-Feed- 33%

49
 REFERENCE

[1] Dilbag Singh and P.Venkateswara Rao “A surface roughness prediction

model for hard turning process” int. J. Adv. Manuf. Technol (2007) 32: 1115-1124
[2] Tugrul Ozel , Tsu-Kong Hsu , Erol Zeren “ Effects of Cutting edge
geometry, work piece hardness, feed rate and cutting speed on surface roughness
and forces in finish turning of hardened AISI H13 steel” int. J. Adv. Manuf.
Techno (2005) 25 : 262-269.
[3] B. Fnides, M.A Yallese, T. Mabrouki, J. F Rigal “Surface roughness model in
turning hardened hot work steel using mixed ceramic tool” ISSN 1392-1207
Mechanika 2009. Nr.3 (77).
[4] Dr. G. Harinath Gowd, M. Gunasekhar Reddy, Bathina Sreenivasulu “
Empirical modelling of hard turning process of Inconel using response surface
surface methodology” Int. J. of emerging technology and advanced engineering,
ISSN 2250-2459, volume2, Issue 10, October 2012.
[5] K. Adersh Kumar et all “ Optimization of surface roughness in face turning
operation in machining of EN-8” International Journal of Engineering Science and
emerging technology Vol 2, issue-4, 807-812, July-Aug 2012.
[6] S.B.Salvi et all “Analysis of of surface roughness in hard turning by using
Taguchi method” international Journal of Engineering science and technology
vol5, No-2 Feb 2013.
[7] F. Puh et all “optimisation of hard turning process parameters with PCBN tool
based on the Taguchi method” Technical Gazette 19, 2(2012), 415-419. 52 | P a g e
[8] Ali Riza Motorcu “The optimisation of machining parameters using the
Taguchi method for surface roughness of AISI 8660 hardened alloy steel” Journal
of mechanical Engineering 56(2010)6, 391-401.
50
[9] R. Ramanujam ET all “Taguchi multi machining characteristics optimisation
in turning of Al-15 SiCp composites using desirability function analysis” Journal
of studies of manufacturing vol-1-2010/Iss2-3 pp120-125.
[10] A.D.Bagawade ET all “The cutting conditions on chip area ratio and surface
roughness in hard turning of AISI 52100 steel” international Journal of Enginering
research and Technology vol 1 Issue-10 December 2012.
[11] S. DeliJaiCov, F. Leonardi, E.C. Bordinassi, G.F. Batalha “ Improved
model to predict surface roughness based on cutting vibrations signal during hard
turning” Archives of materials science and Engineering 45/2 (2010), 102-107.
[12] P.V.S Suresh et all “A genetic algorithm approach for optimisation of surface
roughness prediction model” international Journal of of machine tool and
manufacture 42(2002)675-680.
[13] B. Sidda Reddy et all “ Prediction of surface roughness in turning using
adaptive Neuro-Fuzzy interference system” Jourdan Journal of mechanical and
Industrial Engineering vol-3,Number-4 December 2009, 252-259.
[14] Tugrul O Zel , Yigit Karpat “ Predictive modelling of surface roughness and
tool wear in hard turning using regression and neural net works” international
Journal of machine tools and manufacture 45(2005) 467-469.
[15] Y. Kevin Chou, Hui Song “Thermal modelling for white layer predictions in
finish turning” International Journal of machine Tools and Manufacture 45 (2005)
481-495. 53

51