MECHANICAL DEPARTMENT

INDUSTRIAL CASE STUDY

BY ADITYA ITWARE AJAY LEDADE AJINKYA INGOLE AJITESH SORTE AKASH INGOLE A-13 A-14 A-15 A-16 A-17 GUIDED BY: PROF.D.J.TIDKE

1. Company profile and information 2. Manufacturing products and procedure of the production. 3. Machines used in the company & their features and limitations. 4. Problem identification. 5. Causes of the tool wear. 6. Analysis of the different tools and features.

7. Development of the new tool material.

8. General Remarks 9. future possibilities.

 Company Name:
Chief Executive Officer :

Kinetic Gears

Mr. Vishram Jamdar. Raw Material Source: Manish Forging

COMPANY PROFILE:
Business Type:

Supplier, manufacturer Year Of Establishment: 1980 Ownership Type: Sole Proprietorship Annual Turnover: Rs.50 Lakhs 1 Crore. Total Number Of Employees: 11-25 People.

MANUFACTURING PRODUCTS
Heavy Duty Industrial Gears
Mechanical Gears Precision Gears Cutting Tools

Gear Boxes
Automobile Gears Reduction Gears.

Mechanical gear

gear box

precision gear

Gear fan

Reduction gear

GENERAL PROCEDURE
DESIGN DRAWING OF PRODUCT
RAW MATERIAL

JOB DIMENSIONS

RAW MATERIAL INSPECTION

OPERATIONS

FINAL PRODUCT

OPERATIONS
MATERIAL

SIZES

TURNING

SHAVING

HOBBING

SLOTTING

MILLING

DRILLING

HARDENING

FINAL PRODUCT

POLISHING

GRINDING

Machines Used:
Milling
Lathe(cylindrical & turret lathe) Polishing (surface polishing machine)

Hobbing machine
Grinding machine Special Purpose machines(CNCs, VMCs)

CNC MACHINES
In modern CNC systems, end-to-end component

design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production.

 It can be operated by single human or robotic operator

that moves the component from machine to machine. The complex series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design. Normal working temperature is 33C. Cutting tool used in cncs is generally of cemented carbides. HSS and high carbon steel are used at high speed.

Features of CNC Machine

Consistency of workpieces produced
Faster workpiece machining Complexity of workpieces to be machined

Flexibility, faster turn-around, and smaller lots

Easy to handle & safe too.

LIMITATIONS OF CNC MACHINES

In CNC, a "crash" occurs when the machine moves in

such a way that is harmful to the machine, tools, or parts being machined. This results in bending or breakage of cutting tools, accessory clamps, vices, and fixtures, or causing damage to the machine itself by bending guide rails, breaking drive screws, or causing structural components to crack or deform under strain.

 If anything in input changes (workpiece, raw material

hardness or shape), there will be problems the next time the job is run. It requires a great deal of duplicated effort since 3 CNCs are used. Reduced gripping force due to inadequate lubrication can cause malfunction. Moisture can occur in CNC controlling machine.

SIMONS CNC (15- 20LAKHS)

FANUC CNC (20-25 LAKHS)

HOBBING MACHINES
Hobbing is machining process for making gears

spinles and sprockets on a hobbing machine, which is a special type of milling machine. Also called as hobbers fully automated machines can come in different sizes. Uses: cycloid gears, helical gears, worm gear spur gear, involute gear etc.

FEATURES
It is relatively quick and inexpensive.
They are fully automated. Lubrication is required.

HOBBING MACHINE USED IN KINETIC GEARS.

POSSIBLE LIMITATIONS
Size changes during hob shifting. Size changes from part to part Rigidity of gear system and accuracy is reduced due to

long parts in gear trains. Stability of machine tool is adversely affected due to large openings and spaces required for gear boxes. Breaking of gears is possible due to high speed of operation. Thread deformation due to interruption in operation may occur.

TURRET LATHES
The turret lathe is a form of metalworking lathe that

is used for repetitive production of duplicate parts, which by the nature of their cutting process are usually interchangeable.
The general minor problems are like gear wear,

improper electric supply due to which job gets damaged and affect the production rate.

Turret lathe used in KINETIC GEARS.

LIMITATIONS
Rate of tool feeding is slow in turret lathe providing

more fatigue to operators hand. Turret tooling is heavy, cumbersome, and slow to change out. Turning between centers is difficult due to absence of tailstock, compound rest, lead screw. Electric failure may result in reduced output quality.

SURFACE GRINDING MACHINE

A surface grinder is a machine

tool used to provide precision ground surfaces, either to a critical size or for the surface finish. The typical precision of a surface grinder depends on the type and usage, however +/- 0.002 mm (+/- 0.0001") should be achievable on most surface grinders.

EFFECTS ON WORKING MATERIAL

The high temperatures encountered at the ground

surface create residual stresses and a thin martensitic layer may form on the part surface; this decreases the fatigue strength. In ferromagnetic materials, if the temperature of the surface is raised beyond the Curie temperature then it may lose some magnetic properties. Finally, the surface may be more susceptible to corrosion.

VMC

FEATURES:
1. Fully tooled up solutions to meet the customer needs & Tool life management. 2. Chip Conveyor 3. High speed spindle up to 12000 rpm with chillier Flood Coolant System. 4. Coolant through Spindle. 5. Centralized & Programmable Lubrication 6. Carbide tool is generally used.

PROBLEM IDENTIFIED:
1. The machines like different lathes ,hobbing machine,CNCs have the general minor problems like gear wear in the lathes etc. 2. Since the machining work is more in the industry ,we have selected the TOOL WEAR as major problem for the ICS(Industrial Case Study). 3. So, considering this problem we have given the solutions for that.

Causes of the tool wear:

1. Macro transfer type mechanical wear process like abrasion and
adhesion. 2. Micro transfer type therrmochemical process like diffusion

3. electrochemical process like galvanic action, oxidation.

4. Chemical wear is due to interaction between tool and work material in the cutting fluid environment, 5. Mechanical wear is also produced due to : abrasion due to ploughing into softer matrix by hard constituents & segregated carbides etc

adhesion and formation of metallic bonds formed over rubbing surface under load.

Requirement of cutting tools materials:

to prevent failure of cutting tool, the material must posses certain essential requirements

The tool material should be strong & hard enough to withstand the high
pressures without having brittle fracture(RBF=resistant to brittle fracture)

The tool material should be able to retain its strength and hardness at high
operating temperature. The tool material must have sufficient wear resistant i.e. Resistant to adhesion or diffusion at high temperatures

CUTTING TOOL MATERIALS USED GENERALLY:

1. Carbon tool steels 2. Medium alloy steels 3. High speed steels 4. Cast alloy tools

5. Cemented carbide tools

6. Ceramics.

Carbon tool steels: 1. Up to 1870, tools are all of this type only.. 2. Characteristics of the carbon tool steels are, low hot hardness and poor hardenability. 3. Compositions of carbon tool steel would have, carbon=0.8-1.3% silicon=0.1-0.4% manganese=0.2-0.4% 4. Higher the carbon content higher the hardness and high the wear resistance. Medium alloy steels: Differ from the plain carbon steel due to addition of alloy element to improve hardenability used for drills ,taps and reamers. Typical Medium Alloy Tool Steels,% C 1.2 1.2 1.2 S 0.3 0.3 0.3 Mn 0.6 0.7 0.3 Cr 0.5 0.5 0.7 Mo 0.5 0.3 W 1.5 Fe balance balance balance

HIGH SPEED STEELS:

COMPOSITIION: (M-2 HSS)

0.8 % CARBON

2% V
6% W 4% Cr 5% Mo (invented in 1993)

Features: Steel has high hot hardness

HSS tools

Steel can operate at high cutting speed.

Cast Alloy Tools:

1.
2. 3. 4.

These are non-ferrous high temp. Alloys containing

significant amount of cobalt, chromium & tungsten . number of such non-ferrous alloys have been used in cutting tools called as stellites. these cant be heat-treated are used for a cast from a temperature of about 1300*c. Composition: Co=40-50% Cr=27-32% W=14-29% C=2-4%

CEMENTED CARBIDE TOOLS:

In early stages the material was brittle, so difficult to grind & have tendencies of adhesion while machining, But in 1938 it was found that the addition of Tic & TaC which reduces the adhesion properties in machining with steel THREE GROUPS OF METAL CUTTING CEMENTED CARBIDES: 1. WC+Co(for use in machining cast irons and nonferrous metals) 2. WC+Co+(WC-TiC-TaC-NiC) (for steels) 3. TiC+Ni+Mo(for high temp high strength metals) GENERAL CHARACTERISTICS OF CARBIDE TOOLS: 1. High hardness over a wide range of temperature(900*c).

Where, WC=tungsten carbide. Co= cobalt TiC=titanium carbide TaC =tantalum carbide(a kind of carbide ceramic)

Ceramics:
Also Called As Oxide Tool Materials. E.g.: aluminium oxide alumina(Al2O3). Since oxides are relevant to heat and do not soften at elevated temperatures. Oxide cutting tools reflect the high hardness and good wear resistant too.

Firstly introduced in the USA in 1955 and after that its properties are improved a bit till 1964.
Images of some ceramic tools as shown:

Comparison between different tools according to there strength

According to the hardness value:

General remarks :
Materials having high young's modulus are more refractory (more hot hardness

character).
In an example , the hardness & strength oh the HSS fall rapidly above 500*c But cast cobalt alloys are softer than HSS at room temperature are harder at temp. Above 500*c Wide range of carbide characteristic is due to the variation in cobalt content which may vary between 3%-12%.

When cobalt content increased, the carbide becomes more ductile and shock resistant but less refractory. Still some materials recover there hardness value on cooling,

The ceramics,carbides,cast cobalt alloys recover there hardness completely but HC steel
soften irreversibly (above 500*c for HSS).

This is the one reason why HSS tools are limited to operations having working
temperature below 500*c.

Difference b/w tools :

After attaining 500*c

Recovery of the hardness value after cooling.

Development of new tool materials:

During the machining of high strength temp. Resistant (HSTR)alloys commonly known as AERO-SPACE material. so its essential to improve mechanical & thermal strength .

Development in HSS involves ,atomization of pre alloyed HSS followed by consolidation into shanks by powder metallurgy technique, which gives uniform distribution of the

carbide.(smaller size =for better grind inability.)

To increase the wear resistance of HSS, a hard layer contain upto 15%-20% V or Ti may be deposited on tough substrata.

Extremely hard but very thin surface layers have also been developed by VAPOUR

DEPOSTION OF CARBIDES.

FORD motor company uses improved TiC(titanium carbide) tools for cutting purposes because of there LOW density HIGH oxidation resistance ,which is having FOUR TIMES TOOL LIFE THAN other grades of carbides.

Mixture of Al2O3+TiC gives CERMETS, used in high speed machining of hard cast irons& hard steels too.

One of successful combination is (60%TaN+40%ZrB2)=new refractory material.

Development of new tool material:

Development Existing High speed steels Modify com[position (increase hard phase content) Cast cobalt alloys High tungsten, high carbon atomized Co-Cr-W-C Cemented carbides Carbide with high melting matrices Ceramics New refractory materials (TaN-ZrB2) Development in potentialities of tool material.

Some Advanced Tool Materials During Development:

Coated carbides: 1. When a thin film of TiC was deposited on the steel cutting grade of carbide by vapour phase deposition.

2.

A coating of 0.005 mm reduced the tendency of cemented carbide tool to crater.

3.

Coatings are form TiC,TiN,&Al2O3.while TiC & Al2O3 appear to have most

stable layer between the chip and tool. TiN=lowest tool friction.

1.

Coating can be done by physical methods or sputtering BUT for better bonding we should use the CHJEMICAL VAPOUR DEPOSITION where gas like TiCl4 & CH4 is reached on hot surface about 650*c.

2.

Multilayer coatings can also be used .The layer next to TiC which gives stable diffusion barrier(C leaving prevented) and outer layer TiN gives low interface friction.

3.

Coated carbides are more brittle than carbides but used when crater is to be removed.

CUBIC BORON NITRIDE(CBN)

Coating of polycrystalline diamond or cubic boron nitride(CBN) is introduced on the surface of sintered tungsten carbide having Co binder. CBN coated tools are used primarily to machine stainless steel,HSS, and HSTR alloys. Tool life of the CBN tool is EXCELLENT for machining quenched alloy steel for dies.

Tool life of CBN

NOBIUM BASED UCON:

Union carbide developed UCON based on COLUMBIUM(NIOBIUM)consisting

of 50% COLUMBIUM, 30% titanium & 20% tungsten . These are casst, rolled and slit into blanks. Nitrogen is finally diffused intpo the surface at 1650*c to produce hard surface layer. These blanks are usde for machining steel at high speeds and feeds and are not suitable for cast iron or stainless steel or HSTR alloy.

FUTURE POSSIBILITIES:
From the above discussion it is considered that continuous interest in developing new cutting tools may have following new ideas: 1. Thermo-mechanical treatments to produce textural hardening. 2. Internal oxidation to produce very small(10 nm)hard particles that strengthen by precipitation or dispersion hardening. 3. Directional solidification of cast tool materials& casting techniques that eliminate the embrittling action of micro shrinkage cracks. 4. Application of cooling techniques to produce materials of very fine grain size approaching amorphous structure.

It is seen that there are many exciting new possibilities for further development in cutting tool materials.