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Bachelor of Electrical and Electronic Engineering: Assignment
Bachelor of Electrical and Electronic Engineering: Assignment
Bachelor of Electrical and Electronic Engineering: Assignment
Electronic Engineering
Assignment
A.R.S Fernando
Acknowledgement
First, I would like to express my deepest regards to all those who have provided their
assistance and efforts in the process of creating the report on the synthesis of a high-
performance steel alloy suitable for lathe machines. And my thanks go to my colleagues and
team members for their contributions to this project: the work would have been impossible
without their help. We also extend sincere gratitude to the technical advisors who provided
insight and assistance during the research. Finally, it may be important to acknowledge any
sources of support from the organization in which this work was conducted, as such
assistance is invaluable in carrying out the work.
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Executive Summary
This report aims at designing and manufacturing a high-performance steel alloy for lathe
machines to meet some of the major demands such as mechanical properties, heat stability,
and failure. It previews the details of the development of a high-performance steel alloy for
lathe machine application and the material’s critical demands for mechanical performance,
heat endurance, and failure avoidance. Therefore, through the understanding of superior
manufacturing methods on possible failure modes and optimum solutions, this report offers a
systematic investigation to improve the reliability of the lathe machine parts. Specific
recommendations concerning this problem include proper choice of alloying additives,
precise control of the process and effective quality control.
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Table of Contents
1. Introduction ........................................................................................................................ 1
2. Mechanical Properties and Experimental Procedures ........................................................ 4
2.1 Tensile Strength ................................................................................................................ 4
2.2 Hardness ........................................................................................................................... 5
2.3 Toughness ......................................................................................................................... 7
3. Manufacturing Processes.................................................................................................... 9
3.1 Powder Metallurgy ........................................................................................................... 9
3.2 Heat Treatment ................................................................................................................. 9
3.2.1 Stages of Heat Treatment (Figure 9) .................................................................. 9
3.3 Forging ........................................................................................................................... 10
3.3.1 Impression Die Forging .................................................................................... 10
3.3.2 Cold Forging..................................................................................................... 11
3.3.3 Die Forging in Open Form ............................................................................... 11
3.3.4 Rolling Ring Forging Seamless ........................................................................ 11
4. Possible Failures ............................................................................................................... 12
4.1 Fatigue Failure................................................................................................................ 12
4.2 Wear and Abrasion ......................................................................................................... 13
4.3 Thermal Fatigue ............................................................................................................. 13
5. Optimization of Product Quality ...................................................................................... 14
6. Conclusion ........................................................................................................................ 15
7. Recommendations ............................................................................................................ 16
7.1 Composition of The Proposed Steel Alloy ..................................................................... 16
7.2 Key Properties ................................................................................................................ 16
7.3 Alloy Characteristics ...................................................................................................... 17
7.3.1 Microstructure .................................................................................................. 17
7.3.2 Corrosion Resistance ........................................................................................ 17
7.3.3 Machinability ................................................................................................... 17
8. References ........................................................................................................................ 18
9. Appendices ....................................................................................................................... 19
9.1 Appendix 1 ..................................................................................................................... 19
9.2 Appendix 2 ..................................................................................................................... 20
9.3 Appendix 3 ..................................................................................................................... 21
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List of Figures
Figure 1: Modern Lathe Machine (Wikipedia, 2019) ................................................................ 1
Figure 2: Alloy Steel (amardeepsteel, 2024) .............................................................................. 2
Figure 3: Stress-Strain Behaviour for Steel Alloys (steelconstruction, 2017) ........................... 3
Figure 4: Tensile Stress-Strain Curve (French, 1922) ................................................................ 5
Figure 5: Major components of a Rockwell hardness Tester (TEST, 2016). ............................. 5
Figure 6: Rockwell Hardness Test Results Example (Contributors, 2019) ................................ 7
Figure 7: Toughness Testing (Yang, 2012) ................................................................................. 8
Figure 8: Stages of the Powder Metallurgy Processes (Wikipedia, 2020) ................................. 9
Figure 9: Temperature Ranges for Heat Treatment Processes (Buschow, 2001) ..................... 10
Figure 10: Impression Die Forging .......................................................................................... 10
Figure 11: Cold Forging Processes And Arrangement Of Materials ........................................ 11
Figure 12: Methods of Forging (wikipedia, 2019) ................................................................... 11
Figure 13; Patterns of Component Fractures at Fatigue Failure (Yang, 2012) ........................ 12
Figure 14: Thermal Fatigue (Hoerner, 2021) ........................................................................... 14
List of Tables
Table 1: Experimental Procedure Of Tensile Strength Testing .................................................. 4
Table 2: Experimental Procedure Of Hardness Testing ............................................................. 6
Table 3: Experimental Procedure Of Toughness Testing ........................................................... 7
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1. Introduction
Lathe machines Figure 1 are very important in industries, especially in operations that involve
turning, cutting and finishing of metals and wooden materials respectively. These are versatile
machines where the table has two axes While one of the tables remains stationary, the other
rotates around the workpiece so cutting tools can work on the desired area. The extensive
application of lathe machines in applications like motor vehicle production, production of
aircraft and other transport equipment, metal and wood industries etc. is an indication of the
fact that lathe machines are useful in the manufacturing of a variety of parts right from simple
cylindrical form to near complicated shapes. Regarding the material used for the construction
of lathe machines, it is quite clear that their overall efficiency and lifespan are determined by
this factor. Of all these materials, steel alloys are highly essential as they can provide high
intensity, high toughness, and ease in their processing (Wikipedia, 2019).
To achieve the maximum possible functionality and durability of a lathe machine, specialized
steel alloys in its parts, including spindles, tool holders, and cutting tools, should have special
qualities that determine the stability of their performance. Some of these properties include
Mechanical properties namely the inherent strength of the material Heat resistance The ability
of the material to resist different types of failure. Because of hardness, strength, and toughness,
mechanical capability is recognized as one of the most essential properties of any material.
These properties, therefore, make the steel alloy capable of handling the mechanical loading
and unloading that come along with the machining exercises without further deformations or
even failure. Tensile strength, as a characteristic of the cutting material, enables it to resist such
forces that pull on it and hardness, enables it to resist wear and abrasion due to friction with the
workpiece or the cutting tools.
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Fatigue resistance is crucial since the importance of impact energy for weight-carrying vehicles
and components would otherwise lead to brittle failure under shock loads. Machining processes
of the lathe sometimes develop large amounts of heat due to the rubbing action of the cutting
tool and the workpiece material. For this reason, the steel alloy needs to offer good heat
resistance to still afford the necessary mechanical will, power and fabrication properties at high
temperatures. High-temperature stable alloys that do not undergo mechanical degradation or
exhibit thermally activated failure, are highly desirable for applications where material
performance is susceptible to thermal cycling and thermal stresses, leading to thermal fatigue
failure. It is common for extremely high temperatures to be produced due to the friction of the
cutting tool material against the workpiece. Hence, the steel alloy Figure 2 is required to possess
a high level of heat resistance given the mechanical properties that have to be retained when
the pressure vessel is exposed to high operating temperatures.
Materials that have high-temperature stability, and do not have high thermal sensitivity are
important in preventing many issues that arise from overheating or thermal stress. They are also
supposed to resist some different kinds of failures, and this is, in fact, one of the key
characteristics of high-performance steel alloys that are used in the construction of lathe
machines. Some of the failure modes include fatigue failure, wear and abrasion failure, and
thermal fatigue failure. Toughness is the ability of the steel alloy to absorb energy without
failing through the process of ductile fracture, so an ideal steel alloy must be engineered to
resist these failures through optimized composition and microstructure (amardeepsteel, 2024).
The research topic of this report is the creation of an ultra-high-performance steel alloy
appropriate for use in lathe machines. It aims at achieving an optimum alloy that could exhibit
mechanical flexibility, heat stability, and negligible tendency towards failure. Based on these
requisites, the development of the novel alloy aspires to increase both the service life and
functionality of lathe machine parts in practical usage for refining the accuracy of machining
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processes. It is to the above concern that the following sections of this report will expand on
the technical requirements that would help in achieving this goal. Considering the above-
discussed findings and based on an intricate research and technical evaluation process, this
report seeks to lay an extensible groundwork to produce a high-performance steel alloy that
holds the capability to meet contemporary manufacturing requirements (steelconstruction,
2017).
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2. Mechanical Properties and Experimental Procedures
4
The tensile strength is calculated by,
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑜𝑎𝑑
Tensile Strength =
𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝐶𝑟𝑜𝑠𝑠−𝑆𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑟𝑒𝑎.
2.2 Hardness
Material hardness is defined as the capability of a material to resist deformation, permanent
deformation, indentation, or scratching among other effects. Higher hardness level or high
tensile strength signifies improved wear or abrasive resistance possessed by the lathe machine
parts, in other words, durability. Hardness helps to make sure, that the cutting tools and the
other elements of machinery can resist abrasive power during the process of machining and will
not wear out too quickly (Contributors, 2019).
Data Analysis The hardness value is calculated based on the depth or size
of the indentation
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Many hardness testers are equipped with software to analyse indentation data, calculate
hardness values, and store results for further analysis.
2.3 Toughness
Toughness is the measure of the ability of a material to I an amount of energy before it fractures
under a process of plastic deformation. It is a relieving property that helps in avoiding a
system’s collapse during high shock forces or high-stress loads. Toughness allows the material
to resist shocks or impacts that on occasion must be applied, and this will go a long way in
enhancing the reliability as well as safety of lathe machine components (Yang, 2012).
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Testing Setup Secure the specimen in the impact tester, ensuring
proper alignment.
Verify the calibration of the impact tester before the
test.
Measurement The impact tester releases a pendulum to strike the
notched specimen, fracturing it.
The machine measures the energy absorbed by the
specimen during fracture.
Data Analysis The toughness of the material is calculated based on the
energy absorbed during the impact.
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3. Manufacturing Processes
The manufacturing processes are instrumental in defining the character as well as capability of
the steel alloy.
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Figure 9: Temperature Ranges for Heat Treatment Processes (Buschow, 2001)
3.3 Forging
In this case, forging can be described as the process of using forces that are compressive in the
shaping of the metal. The involved process refines the grain structure and enhances the features
such as toughness and strength in the alloy. It is a known fact that forged components are highly
reliable and are also more resistant mechanically than cast components. To shape metal
products, four types of forging manufacturing methods are widely employed. These methods
of forging metal include cold forging, open die forging, seamless rolled ring forging, and
impression die forging (closed die) (wikipedia, 2019).
The impression dies forging method, also known as closed die forging, uses dies that completely
encapsulate the base material, which facilitates the material's shaping into the required shape.
Impressions die forging demands higher compressive forces than other forging processes to
guarantee that the die cavities are filled, and the item is completed.
The goal of the cold forging process is to produce parts and components with tight tolerance
dimensions and improved surface finish quality. In contrast to most other forms of forging, cold
forging uses lower temperatures to create a variety of components rather than heat to shape the
part's structure.
Direct force is used to mould open die-made pieces, which is also known as hammersmith
forging. Two flat dies hold the workpiece in place as the hammer impacts and distorts it. Since
the workpiece is not enclosed by the dies, this process is known as open-die forging. In this
sense, the dies function less as enclosed moulds and more like tools.
Seamless rolled ring forging techniques are perfect for creating rings with diameters ranging
from a few inches to thirty feet. They usually include punching a hole in a big, spherical piece
of metal, rolling and then compressing the doughnut into a thin ring. In contrast to previous
methods, rolled ring forging forms ring-shaped components by using curved dies rather than
flat dies.
Causes:
Substantial vibratory loads on the structure due to the cycle of stress by using the lathe
machine.
Stress raisers including grooves, corners, or defects on the surface.
Incorrect heat treatment process or incorrect treatment of the surface of the material.
Introduce alloying elements that yield higher fatigue strength, chromium, molybdenum,
and vanadium for instance.
To improve the grain structure, minimize residual stress and increase ductility right
forgings and heat treatments are done.
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4.2 Wear and Abrasion
Fatigue and rubbing are common phenomena, which happen through the wearing out of the
alloy material that meets the workpiece or cutting tools for a long time and causes loss of
material and surface deterioration. This kind of failure regularly occurs in the components of
lathe machines such as tool holders and spindles.
Causes:
It is the force of resistance or interaction between the component surfaces and the
workpiece.
Dust in working areas, sand, and other small particles.
Inadequate lubrication.
Thermal fatigue occurs due to cyclic thermal stresses from repeated heating and cooling
during the operation of the lathe machine. This can lead to the initiation and growth of
thermal cracks, which may eventually cause the component to fail.
Causes:
Select alloys with high thermal stability and low thermal expansion coefficients, such
as those containing nickel or cobalt.
Use proper heat treatment processes to enhance the thermal fatigue resistance of the
alloy, such as tempering to relieve internal stresses.
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Implement effective thermal management strategies, including the use of coolants and
optimized machining parameters to minimize temperature fluctuations.
Material Selection
It is very important to decide which alloying elements provide the increase of the desirable
mechanical characteristics. Minerals such as chromium, vanadium and molybdenum help in
increasing the hardness, tensile strength, and toughness.
Process Control
Process control is the final element that separates the various steps involved in manufacturing
from ensuring that quality is always maintained. This covers the areas of heat treatment and
forging, whereby the authorities fix the temperature, pressure, and rates of cooling.
Quality Assurance
It is also relevant to adopt a comprehensive system of quality control, which includes systematic
testing and inspection of the product to determine weaknesses and irregularities as soon as
possible. To carry out an inspection and discover internal flaws, there are methods like non-
destructive testing or NDT in short.
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6. Conclusion
Methods of making steel alloys are of utmost importance when it comes to the final
characteristics of the manufactured manufacture product. Thus, the application of powder
metallurgy, heat treatment, and forging are three methods which may be employed to fine-tune
several properties of the alloy. Through powder metallurgy, one can really and truly control the
composition of the alloy and the grain structures and hence there is an improvement in the
mechanical characteristics. The application of annealing, quenching, and tempering methods
enhances the control of the alloy microstructure, impacting hardness, strength, and toughness.
It is of importance for forging aims at improving the grain structure depending on the type of
the alloy that leads to better and more reliable strength and durability. It is important to identify
and address potential breakdowns to enhance the overall quality and effectiveness of the steel
alloy. They may fail due to fatigue failure, wear and abrasion, and thermal fatigue failure,
especially on the cutting tool and other moving parts of the lathe machine. Fatigue failure is the
failure as a result of stacks of cyclic loading that causes cracks to form and grow. It is the
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wearing a way whereby the surfaces are in constant rubbing contact leading to material removal
and damage to the working surfaces. Thermal fatigue is found due to cyclic heat and cool
stresses, where the material is exposed to changes in temperatures cyclically. All these failure
modes are mitigatable through material selection, optimization of the processing methods
applied, and the surface treatments carried out.
7. Recommendations
Carbon, chromium, and vanadium all played their part in enhancing the tensile strength of the
component implying that high pulling forces are achievable during normal machining.
Chromium aids forte and increases the wear capability of the cutting tool in continuous usage,
tungsten boosts the hardness and enhances the toughness of the tool, and cobalt helps in
providing better heat resistance. Molybdenum and vanadium enhance the ‘tensile’ properties of
the alloy and make the metal tougher and more capacitive to absorb impact energy thereby
reducing the tendency to brittle fracture. By incorporating chromium, tungsten and cobalt into
the alloy, the material retains the required mechanical properties and performance at high
temperatures so eliminating the issue of thermal fatigue is achieved.
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7.3 Alloy Characteristics
7.3.1 Microstructure
In this way, various cooling and heat treatments are used to refine the grain size of the alloy
either into mar antagonistic or gain antagonistic structures that have better mechanical
properties.
Chromium and cobalt are effective in boosting the corrosion protection of the alloy and thus
serve the alloy in different operational environments for quite a long period.
7.3.3 Machinability
Even though the cylindrical alloy expresses extremely high hardness and strength, it also offers
good machinability due to its proper metallurgical construction and fine grains thus enabling
easy, effective and accurate turning to be made on the material.
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8. References
amardeepsteel, 2024. PROPERTIES AND USES OF ALLOY STEEL. [Online]
Available at: https://www.amardeepsteel.com/blog/SpecificBlog/1/
ASTM, 2024. Test Methods for Tension Testing of Metallic Materials. [Online]
Available at: 10.1520/e0008_e0008m-22
Buschow, K., 2001. Encyclopedia of materials : science and technology. Oxford: Elsevier.
Contributors, W., 2019. Brinell scale. [Online]
Available at: https://en.wikipedia.org/wiki/Brinell_scale
Ducheyne, P., 2015. Comprehensive biomaterials. 5 ed. s.l.:Amsterdam Elsevier.
French, H., 1922. Tensile properties of some structural alloy steels at high temperatures.
Journal of the Franklin Institute, 193(2), pp. 249-250.
Hoerner, D. M., 2021. Turbomachinery: How metals break: the materials of metallurgical
failure. s.l.:KnightHawk Materials Lab.
International, A., 2023. Charpy Impact Test: ASTM E23. [Online]
Available at:
https://www.wmtr.com/en.charpy.html#:~:text=The%20Charpy%20Impact%20Test%20consis
t
steelconstruction, 2017. Steel material properties. [Online]
Available at: https://www.steelconstruction.info/Steel_material_properties
TEST, H., 2016. Digital Display Brinell Rockwell Vickers Universal Hardness Tester. [Online]
Available at: https://hsttest.en.made-in-china.com/product/WSYxyREvOfpV/China-Hbrvs-
187-5-Digital-Display-Brinell-Rockwell-Vickers-Universal-Hardness-Tester.html
wikipedia, 2019. Forging. [Online]
Available at: https://en.wikipedia.org/wiki/Forging
Wikipedia, 2019. Lathe. [Online]
Available at: https://en.wikipedia.org/wiki/Lathe
Wikipedia, 2020. Powder metallurgy. [Online]
Available at: https://en.wikipedia.org/wiki/Powder_metallurgy
Yang, Z., 2012. Achieving high strength and toughness in a Zr–2.3Nb alloy by the formation
of duplex microstructure. Materials & Design.
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9. Appendices
9.1 Appendix 1
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9.2 Appendix 2
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9.3 Appendix 3
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