International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 6 (2018) pp.

209-214
© Research India Publications. http://www.ripublication.com

Chip Morphology Study during Turning of AISI 304l Alloy Steel under
Different Cutting Fluid Conditions

Gunjan Sharma1
Research Scholar, Department of Mechanical Engineering Research,
Global Institute Of Technology, Jaipur, India

Sharad Shrivastva2
Assistant Professor, Department of Mechanical Engineering,
Rajasthan Institute of Engineering and Technology, Jaipur India

Abstract chamfered tool. It found that all the phenomenon occurring

Chips are produced during turning operation. Due to the were same except thrust force it increases with chamfer angle
formation of chip heat energy is loss. The chip handling and along with length. Hsu et. al [8] concentrated coefficient of
disposal is always a tough process. Steel alloys are most friction during turning operation. He analyzed about its
widely used material in aerospace and industries. Hence it variation during the contact area between the chip and tool
becomes important to study about chip formation in the way interface. After changing the depth of cut and contact length
of its structure, dimension, and process of separation while cutting forces increases. Boothroyd et. al [9] concentrated
turning. This research revealed about chip morphology of their research work on cutting condition. According to them
steel alloy AISI 304l, in terms of chip types and chip chip thickness depends upon shear angle in turning process.
appearance and shape with TNMG carbide tool insert. Three This paper focused on favorable or unfavorable chip
different cutting environments of semi-synthetic cutting oil, formation during the turning process of AISI 304L materials.
rice bran oil and canola oil were chosen. Feed rates of 0.1,
0.15, and 0.2 mm/rev and Cutting speeds of 100,200,300 Methodology
m/min are chosen for experiment with depth of cut of 0.4,0.6 The experimental works in this research were conducted on
and0.8 mm AISI 304L alloy steel with original hardness of 60 HRB using
a MAXTURN PLUS+ model of CNC lathe machine. TNMG
Keywords:: Turning Process, Chip Morphology, Cutting 160408 carbide inserts was employed in the experiments. The
Environment. turning experiments were conducted with three different
cutting fluid conditions. Table I shows the chemical
Introduction composition of AISI 304L alloy steel.
The chip production is an output of cutting, which affects the
tool life, surface quality, and job piece finishing the chip Table 1: Chemical composition of AISI 304l
formation is very important for optimizing the machining
output. Zorev et. al [1], revealed that high speeds and heavy Element car chromi iron manga nick phos
loads gives higher changes in chip and higher cutting bon um nese el phor
temperatures during machining. N. Narutaki et. al [2] us
investigated on the tribological issues higher load gives sever Availabil 0.0 18-20 balan 2 max 8- 0.04
damage to the jobpiece. P. Fallbohmer et. al [3] researched on ity 3 ce 12 5
Machining with harden steel gives higher temperature which ma max
affects the chip flow and it gives the lower cutting force. x
Through machining of harden steel in the duration of high
cutting speed to low feed rate continuous chips were obtained. The value of speed, feed, depth of cut and cutting oil
I. El-Wardany et. al [4] discussed about the Cutting edge of conditions were taken which is represented in table II
the tool is subjected to various force during the operation. Due
to this variation in cutting force chip formation affects and Table 2: various factor and level
segmental chips are formed which reduces cutting force. T.
Kitagawa et. al [5] experimentally determined that By Factor 1 2 3
increasing the cutting speed separation of chip occurs Speed 100 200 300
smoothly but along with this tool wear or crater wear in that Feed 0.10 0.15 0.20
increases the chip thickness decreases .Merchant et. al [6] Depth of Cut 0.4 0.6 0.8
studied about impact of tool geometry on chip formation. It Cutting Fluid Semi- Rice bran Canola oil
covered both type of geometry which appears in cutting synthetic oil oil
condition. Hirao et al. [7] find out the impact of tool on chip
production the study was on both type of chamfered and non

209
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 6 (2018) pp. 209-214
© Research India Publications. http://www.ripublication.com

Chips from all the experiments were obtaining them to

analyze the chip structure, dimension and its thickness. The
thickness of the chips was measured by using a précised
micrometer with accuracy of ±0.001 mm. cutting ratio of the
chip from turning process can be calculated by given formula
[10]:

Where:
Figure 1: Impact of depth of cut and feed on chip
tc – measured chip thickness
formation
to - undeformed chip thickness
From the calculated value of cutting ratio and rake angle of It is shown in Table IV to table VI below that the thickness of
the insert, shear angle can be calculated by using following the chips produced during the turning operation are reduced
formula [10]: at the stage of maximal cutting velocity, minimal feed rate ,
and lower depth of cut. chip thickness deduction gives lower
cutting force which is requires for the shearing of the chip
Where phi is the shear angle, from jobpiece [14] and gives improved chip deformation
r is the cutting ratio, process too[10].. Basically shear angle, chip thickness and
α is the rake angle of the insert. shear plane are co associated with each other. According to
this theory larger the shear angle and thinner the chip
From the value of insert’s rake angle and resulted shear angle, produces during any cutting operation [15].All researches
the value of coefficient of friction can be calculated as in [11]: prove that during turning process friction coefficient reduces
by increasing shear angle[16].In addition, the value of cutting
ratio also plays an important role to determine the resulted
shear angle, hence also the coefficient of friction [12].
Where μ is the coefficient of friction, and can be finding out
Although it was analyzed that lower the temperature of tool
from the below [11]:
chip interface it reduces the adhesion of chip from the rack
face of tool and chip clinging can be avoided .instead of this at
higher temperature chip sticking and adhesion problem arises
at tool rack phase[10]. . Chip appearance and size is also
Experimental Result and Discussion important from the chip distortion point of view, longer chips
The measured values of chip thickness are grouped according tend to collect around tool and job piece and sometimes on
to the parameters and cutting environment conditions are machined surface also, which distort the finishing of
tabulated to find out the comparison of chip formation under machined part and makes inconvenience in tool motion.
the effect of different machining parameters. According to the Therefore they are regarded as unfavorable condition of chip.
structure, appearance and dimension and type of the chips Chip which is small in structure and shape never tries cling to
formed during the cutting processed is divided in to 5 the jobpiece and also tries not to distort the surface
categories [12] as in Table III below. The dependency of the smoothness of workpiece. With semi synthetic oil, all chips
chip shape on the cutting parameters, specifically depth of cut are continuous and regular in shape and size, the diameter of
and feed rate is shown in Fig.1 [13] chip is increasing with increasing the depth of cut. In rice bran
oil cutting oil condition the thickness increase with depth of
Table 3: Type of chips cut increment but the appearance and size remains almost
similar because cooling with conventional coolant restricts the
type temperature rise abruptly, which avoid the weakening of chip.
of However, for canola oil condition, not only the thickness of
1 2 3 4 5
chip chip rises with higher depth of cut but also the appearance and
size also changes due to blunt change in the hardness of chips.
Helical Helical Helical
C& Ɛ Helical
small medium long
cracked uncracked
cracked cracked cracked
chip chip
chip chip chip

210
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 6 (2018) pp. 209-214
© Research India Publications. http://www.ripublication.com

For semi synthetic oil

Run no. Cutting oil speed Feed Depth of cut Chip created Chip thickness form of chip
1 Semi-synthetic oil 100 0.1 0.8 0.22 Helical uncracked chip

2 100 0.15 0.4 0.4 Helical long cracked chip

3 100 0.2 0.6 0.25 Helical medium cracked chip

4 200 0.1 0.8 0.32 Helical small cracked chip

5 200 0.15 0.6 0.36 Helical medium cracked chip

6 200 0.2 0.4 0.21 Helical long cracked chip

7 300 0.1 0.6 0.37 Helical uncracked chip

8 300 0.15 0.4 0.16 Helical long cracked chip

9 300 0.2 0.8 0.38 C & Ɛ cracked chip

211
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 6 (2018) pp. 209-214
© Research India Publications. http://www.ripublication.com

For Rice Bran Oil

Depth of Chip form of

Run no. Cutting oil speed Feed Chip created
cut thickness chip
1 Helical
small
100 0.1 0.8 0.25 cracked
chip

2 C& Ɛ
cracked
chip
100 0.15 0.4 0.21

3 Helical
medium
cracked
100 0.2 0.6 0.32
chip

4 Helical
medium
200 0.1 0.8 0.16 cracked
chip

5 Helical
Rice bran medium
oil 200 0.15 0.6 0.32 cracked
chip

6 Helical
medium
cracked
200 0.2 0.4 0.4
chip

7 Helical
long
300 0.1 0.6 0.33 cracked
chip

8 Helical
long
cracked
300 0.15 0.4 0.17 chip

9 Helical
uncracked
chip
300 0.2 0.8 0.22

212
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 6 (2018) pp. 209-214
© Research India Publications. http://www.ripublication.com

For Canola Oil

Run no. Cutting oil speed Feed Depth of cut Chip created Chip thickness form of chip
1 Canola oil 100 0.1 0.8 0.32 C & Ɛ cracked
chip

2 100 0.15 0.4 0.28 Helical

uncracked chip

3 100 0.2 0.6 0.2 Helical small

cracked chip

4 200 0.1 0.8 0.15 Helical small

cracked chip

5 200 0.15 0.6 0.27 Helical medium

cracked chip

6 200 0.2 0.4 0.37 Helical medium

cracked chip

7 300 0.1 0.6 0.17 Helical long

cracked chip

8 300 0.15 0.4 0.17 Helical

uncracked chip

9 300 0.2 0.8 0.2 Helical long

cracked chip

213
 International Journal of Applied Engineering Research ISSN 0973-4562 Volume 13, Number 6 (2018) pp. 209-214
© Research India Publications. http://www.ripublication.com

Conclusion [13] K. DeBenedictis, “Read your Chips,” Modern Machine

From this work study above, some results are reveled which Shop, 1998. [Online]. Available:
Can be concluded as: http://www.mmsonline.com/articles/read-your-chips.
(1) After accumulating the chips in all cutting fluid conditions [14] R. Suresh, S. Basavarajappa, V. N. Gaitonde, and G. L.
chips in canola oil cutting fluid condition are discontinuous, Samuel, “Machinability investigations on hardened AISI
irregular in structure and size because of brittle fracture, 4340 steel using coated carbide insert,” Int. J. Refract.
which is desired for an efficient machining process Met. Hard Mater., vol. 33, pp. 75–86, Jul. 2012.
(2) Chip thickness rises up with rising in cutting velocity and
feed amount while canola oil by comparing two other oil [15] M. Stanford, P. M. Lister, C. Morgan, and K. A. Kibble,
(semi synthetic and rice bran oil) appeared to restrict the rise “Investigation into the use of gaseous and liquid nitrogen
in chip thickness. as a cutting fluid when turning BS 970-80A15 (En32b)
(3) Depth of cut plays indispensable role in chip thickness plain carbon steel using WC–Co uncoated tooling,” J.
with higher depth of cut chip diameter increases. Mater. Process. Technol., vol. 209, no. 2, pp. 961–972,
Jan. 2009.
References [16] S. Y. Hong, Y. Ding, and W. Jeong, “Friction and cutting
[1] N. N. Zorev, Metal Cutting Mechanics. Pergamon Press, forces in cryogenic machining of Ti–6Al–4V,” Int. J.
1966. Mach. Tools Manuf., vol. 41, no. 15, pp. 2271–2285, Dec.
2001.
[2] N. Narutaki, Y. Yamane, S. Tashima, and H. Kuroki, “A
New Advanced Ceramic for Dry Machining,” CIRP Ann. [17] Y. Yildiz and M. Nalbant, “A review of cryogenic
- Manuf. Technol., vol. 46, no. 1, pp. 43–48, 1997. cooling in machining processes,” Int. J. Mach. Tools
Manuf., vol. 48, no. 9, pp. 947–964, Jul. 2008.
[3] P. Fallbohmer, C. A. Rodriguez, T. Ozel, and T. Altan,
“High Speed Machining of Cast Iron and Alloy Steels for
Die and Mold Manufacturing,” J. Mater. Process.
Technol., vol. 98, pp. 104–115, 2000.
[4] T. I. El-Wardany, E. Mohammed, and M. A. Elbestawi,
“Cutting temperature of ceramic tools in high speed
machining of difficult -to-cut-materials,” Int. J. Mach.
Tools, vol. 36, no. 5, pp. 611–634, 1996.
[5] T. Kitagawa, A. Kubo, and K. Maekawa, “Temperature
and wear of cutting tools in high speed machining of
inconel and Ti-6Al-6V- ZSn,” Wear, vol. 202, pp. 142–
148, 1977.
[6] E. Merchant, “Mechanics of Metal Cutting Process;
Orthogonal and Type 2 Chips,” J. Appl. Phys., vol. 16,
no. 5, pp. 267–275, 1945.
[7] M. Hirao, J. Tlusty, R. Sowerby, and G. Chandra, “Chip
formation with chamfered tools.,” J. Eng. Ind., vol. 104,
pp. 339–342, 1982.
[8] T. C. Hsu, “A Study of the Normal and Shear Stresses on a
Cutting Tool,” J. Eng. Ind., pp. 51–64, 1966.
[9] G. Boothroyd, “Effect of Surface Slope on Shear Angle in
Metal Cutting,” J. Eng. Ind., pp. 115–118, 1970.
[10] B. D. Jerold and M. P. Kumar, “Experimental
investigation of turning AISI 1045 steel using cryogenic
carbon dioxide as the cutting fluid,” J. Manuf. Process.,
vol. 13, no. 2, pp. 113–119, Aug. 2011.
[11] M. P. Groover, Fundamentals of Modern Manufacturing,
2nd editio. John Wiley & Sons Inc., 2002.
[12] N. R. Dhar, N. Sarmin, K. Paul, N. Nahar, and D. Alam,
“Chip Formation in Turning Medium Carbon Steel by
Uncoated Carbide Inserts under Dry , Wet and High-
Pressure Coolant Conditions,” in International
Conference on Mwchanical Engineering 2007, 2007, vol.
2007, no. December, pp. 29–31.

214