laboratory report on manufacturing lab -1

37
“Perform turning operation on High carbon steel and estimate power required for turning” Submitted by SUNITHKUMAR H GURADDI USN: 1RV15MCM17 Under the Guidance of Dr. Gopalakrishna H D Professor and Associate Dean VISVESVARAYA TECHNOLOGICAL UNIVERSITY BELGAUM-590018 Laboratory seminar on Department of Mechanical Engineering R V College of Engineering

Transcript of laboratory report on manufacturing lab -1

Page 1: laboratory report on manufacturing lab -1

“Perform turning operation on High carbon steel and estimate power required for turning”

Submitted bySUNITHKUMAR H GURADDI

USN: 1RV15MCM17 

Under the Guidance ofDr. Gopalakrishna H D

Professor and Associate Dean

VISVESVARAYA TECHNOLOGICAL UNIVERSITYBELGAUM-590018

Laboratory seminar on

Department of Mechanical EngineeringR V College of Engineering

Page 2: laboratory report on manufacturing lab -1

Contents

• Objectives• Introduction• Literature Review• Materials used• Experimental details• Experimental Procedure• Results and Discussion• Conclusion• References

Page 3: laboratory report on manufacturing lab -1

Experiments Conducted

• Major Experiment :“Perform turning operation on mild steel and estimate power required for turning”

• Minor Experiment :“Characterize surface roughness of high carbon steel using grinding machine”

Page 4: laboratory report on manufacturing lab -1

Objective

• The main objective of this experiment is to study of power consumption in turning operation of high carbon steel with carbide tip tool.

• The study shows the influences of three cutting parameters like spindle speed, depth of cut and feed rate are affecting power consumption.

• The turning operation is done by keeping either one parameter constant such as spindle speed or feed rate and depth of cut.

• Since the productivity and quality is the main challenge in metal cutting industry and also it plays an important role in market this experiment takes value.

Page 5: laboratory report on manufacturing lab -1

Introduction• Turning operation using a single point cutting tool has been one of the oldest and

popular methods of metal cutting. Turning is a very important machining process in which a single point cutting tool removes unwanted material from the surface of a rotating cylindrical work piece.

• Cutting forces are the background for the evaluation of the necessary machining power, as well as for dimensioning of the tools.

• Turning produces three cutting force components the main cutting forces are thrust force, (Fz), which acts in the cutting speed direction, feed force, (Fx), which acts in the feed rate direction and the radial force, (Fy), which acts in radial direction and which is normal to the cutting speed.

• Out of three force components the cutting force (main force) constitutes about 70% to 80% of the total force ‘F’ and is used to calculate the power ‘P’ required to perform the machining operation.

• Power is the product of main cutting force and the cutting velocity and is given by P= Fy*V

Page 6: laboratory report on manufacturing lab -1

Literature Review• Metal cutting and forming have been traditionally the most common manufacturing

processes from the old ages. Machining processes have been here for a long time but scientific researches on machining started only during 19th century.

• M. Adinarayana, et al. [1] studied optimization of power consumption in turning operations using CVD cutting tool on AISI 4340 Alloy Steel with speed, feed and depth of cut as a control parameters. Result obtained was, power consumption is increase with increase in cutting speed, feed rate and depth of cut.

• R. Suresh, et al.[2] studied that performance of cemented carbide tool on machining of hardened AISI 4340 steel using Taguchi approach in turning process by cutting speed, feed and depth of cut as a controlled factor and power consumption as performance measure. Result found was cutting speed has the highest influence on the machining power required to perform machining operation (77.67%) followed by feed rate (17.39%) and depth of cut (2.82%).

• D. Babu, et al. [3] studied optimization of power consumption using Taguchi's technique. Experiment was conducted with an extruded aluminium shaft on a CNC lathe with cutting speed, feed rate and depth of cut as process parameters. It was observed that the feed rate and the depth of cut are greatly influencing the power consumption.

Page 7: laboratory report on manufacturing lab -1

Literature Review Continued…• H. Singh, et al. [4] investigated the effects of cutting parameters like

spindle speed, feed and depth of cut on EN-8 using HSS tool on CNC Lathe. The results found was, spindle speed contributed 63.90%, depth of cut contributed 11.32% and feed rate contribution was 8.33%.

• D. Singh, et al, [5] investigated the effects of cutting parameters like spindle speed, feed and depth of cut on surface finish and material removal rate on EN-8 under turning conditions on CNC lathe by using carbide tool. Result found was that speed and depth of cut are put negligible effect on the cutting forces and feed rate shown increasing trend.

• K. Kumar, et al. [6] investigated influence of cutting forces in facing operation of EN-8 using cemented carbide insert. Experiment conducted by using three levels of cutting speed (100, 360, 560) rpm, three levels of feed (0.14, 0.15, 0.16) mm/rev and three levels of depth of cut (0.5, 1, 1.5) mm. Result was found that the effect of feed rate is more considerable than cutting speed on cutting forces.

Page 8: laboratory report on manufacturing lab -1

Materials Used-High carbon steelProperties of high carbon steel• Carbon content is over 0.8% and less than 2.11%.• It has a reputation for being hard, but the extra carbon makes it brittle than other type

of steel.• High C content provides high hardness and strength.• Hardest and least ductile.• Used in hardened and tempered condition

Chemical composition

Carbon Manganese Silicon Sulphur Phosphorous Other0.35-0.45% 0.60-0.95% 0.10-0.35% 0.05% 0.05% 0.1%

Page 9: laboratory report on manufacturing lab -1

Experimental Details• In the experiment cylindrical High carbon steel work piece is turned on

conventional lathe by keeping the parameters such as feed rate or cutting speed constant and at same depth of cut.

• The material used for the experiments is grade EN-18 high carbon steel, The work piece is of 150mm in length and 40mm in diameter.

• During turning operation the cutting forces acts on the tool, which is measured using Lathe tool dynamometer.

Fig. Lathe tool dynamometer

Page 10: laboratory report on manufacturing lab -1

Experimental Setup

Fig. Cutting forces acting on tool

Fig. Conventional Lathe with lathe tool dynamometer

Page 11: laboratory report on manufacturing lab -1

Experimental Procedure

• High carbon steel is selected of diameter 40mm and length 150mm.• The surface is cleaned to carry turning operation.• The work piece is placed in the chuck of the lathe machine.• Carbide tip cutting tool is selected for metal removal process.• Now Depth of cut is given as 0.5mm, feed as F=0.14mm (constant).• First, diameter of high carbon steel reduced by 2mm and process is carried

out by keeping feed constant and by varying the speed.• Next, diameter of high carbon steel is reduced by 2mm and process is carried

out by keeping speed constant and by varying the feed.• When conventional lathe machine is turned ON, carbide tip tool starts

removing the material and plane turning is formed at constant feed and varying speed.

• Power required for turning process is given by

Page 12: laboratory report on manufacturing lab -1

Result and Discussion

• (A)Feed constant and Cutting Speed varies Feed (constant)= 0.14 mm DOC = 1.0 mm

Tabular Column at Constant feed

Page 13: laboratory report on manufacturing lab -1

(B) Feed varies and Cutting Speed constant Speed (constant)= 100 rpm DOC = 1.0 mm

Tabular Column at Constant speed

Page 14: laboratory report on manufacturing lab -1

Spindle speed v/s Power consumption

. 63 100 160 220 360

0

0.1

0.2

0.3

0.4

0.5

0.6

Speed v/s Power

Power required

It has been observed from graph that as spindle speed increases gradually power consumption increases. Increase in speed improves surface finish at a cost of power consumption.

Page 15: laboratory report on manufacturing lab -1

Feed v/s Power consumption

.

0.14 0.15 0.16 0.17 0.180

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0.16

Feed v/s Power

Power required

Graph shows that as feed increases power consumption also increases. Power consumption is observed to be increased when speed, feed rate and depth of cut is increased. The effect of spindle speed, feed rate on power consumption are presented in graphs

Page 16: laboratory report on manufacturing lab -1

Conclusion• The results of the experiment indicated that the three components of the

turning force decrease slightly as cutting speed increases and also they increase linearly with feed rate.

• Increasing the cutting speed and feed increases the power required for turning the high carbon steel.

Page 17: laboratory report on manufacturing lab -1

References1. Adinarayana, M. B, Prasanthi,G. P., Krishnaiah, G. K., “Parametric analysis and multiobjective

optimization of cutting parameters in turning operation of AISI4340 alloy steel with CVD cutting tool”, IJRET, Vol. 3, pp. 449-456, 2014.

2. Suresh, R. B., Basavarajappa, S. K., Samuel, C. K., “Some studies on hard turning of AISI 4340 steel using multilayer coated carbide tool”, Measurement, Vol. 45, pp. 1872-1884, 2012.

3. Babu, D. Y., Kumar, M. G., Vishnuu, J. H., “Optimization of cutting parameter for CNC turned part using Taguchi technique”, International Journal of Engineering, Vol. 13, pp. 493-497, 2012.

4. Singh, H. S., Khanna, R. A., Garg M. T., “Effect of Cutting Parameters on MRR and Surface Roughness in Turning EN-8”, Current Trends in Engineering Research, Vol. 1, pp. 100-104, 2011

5. Singh, D. H., Verma, M. D., “Experimental Investigation of Surface Roughness and MRR in dry turning of EN-8 on CNC Lathe”, International Conference on Advancements and Futuristic Trends in Mechanical and Materials Engineering, Vol. 7, pp. 980-987, 2012.

6. Kumar, K. J., Ratnam, C. S., Murthy, B. R. “Optimization of Surface Roughness In Face Turning Operation In Machining of EN-8”, International journal of Engineering Science & Advance Technology, Vol. 2, pp. 807-812, 2012.

Page 18: laboratory report on manufacturing lab -1

MINOR EXPERIMENT

Page 19: laboratory report on manufacturing lab -1

“Characterize surface roughness of high carbon steel using grinding machine”

Submitted bySUNITHKUMAR H GURADDI

USN: 1RV15MCM17 

Under the Guidance ofDr. Gopalakrishna H D

Professor and Associate Dean

VISVESVARAYA TECHNOLOGICAL UNIVERSITYBELGAUM-590018

Laboratory seminar on

Department of Mechanical EngineeringR V College of Engineering

Page 20: laboratory report on manufacturing lab -1

Contents• Introduction• Literature Review• Experimental Methodology• Results• Conclusions• References

Page 21: laboratory report on manufacturing lab -1

Abstract• Surface grinding is the most common process used in the manufacturing

sector to produce smooth finish on flat surfaces. Grinding is a finishing process used to improve surface finish.

• In grinding, an abrasive material rubs against the metal part and removes tiny pieces of material

• The surface roughness and material removal rate have been identified as quality attributes and are assumed to be directly related to performance of mechanical pieces, productivity and production costs.

• Surface quality and metal removal rate are the two important performance characteristics to be considered in the grinding process. The main purpose of this work is to study surface roughness of high carbon steel (EN24) by talking grit size of grinding wheel and depth of cut as parameters.

Page 22: laboratory report on manufacturing lab -1

Introduction• Grinding is a finishing process used to improve surface finish, abrade hard materials,

and tighten the tolerance on flat and cylindrical surfaces by removing a small amount of material.

• In grinding, an abrasive material rubs against the metal part and removes tiny pieces of material.

• Steel is the one of the important material that is widely used in the construction field. In steel there are many types i.e. made based on the carbon content in the steel. Basically there are three types; they are high carbon steel, medium carbon steel and low carbon steel.

• Roughness is sometimes an undesirable property, as it may cause friction, wear, drag and fatigue, but it is sometimes beneficial, as its texture allows surfaces to trap lubricants and prevents them from welding together.

• Here in our study we are going to study the surface roughness of high carbon steel by surface grinding process

Page 23: laboratory report on manufacturing lab -1

Literature Review

• R. R. Chakule et al. Stated [1] that Grinding machines are generally used for achieving of high dimensional accuracy surfaces and good surface finish. They used taguchis method for the analysis. They found that three parameters namely table speed, depth of cut and coolant flow rate has effect on surface roughness of the material.

• Balwinder Singh et al. Stated [2] that the grinding process is the material removal and surface process. The product quality depends very much on surface roughness. They studied about the surface roughness of mild steel by surface grinding machine. They found that surface grinding process parameters like inlet pressure of coolant, grinding wheel speed, and table speed and nozzle angle have affect on the quality of the finished mild steel work-piece.

• Lijohn P George et al. Stated that [4] grinding is an essential process for final machining of components requiring smooth surfaces and precise tolerances. They studied on EN24, EN31 and EN 353 for the parameters depth of cut, material hardness and work piece speed on surface roughness by Taguchi’s method. They concluded that optimum values of depth of cut, hardness, and speed which gives minimum surface roughness.

Page 24: laboratory report on manufacturing lab -1

Literature Review Cont.......

• Pavan Kumar et al. Stated [5] Surface grinding is the most common process used in the manufacturing sector to produce smooth finish on flat surfaces. The main purpose of this work is to study the effects of abrasive tools on EN24 steel surface by using three parameters grinding wheel speed, table speed & Depth of cut. They found that the optimal combination of parameter settings are wheel speed of 850RPM, table speed of 15m/min and Depth of cut of 11.94μm for achieving the required maximum MRR and minimum surface roughness.

• From the various studies done we can conclude that depth of cut, feed rate, speed of wheel, grit size of the grinding wheel will effect the surface roughness of work piece.

Page 25: laboratory report on manufacturing lab -1

Experimental Methodologywork piece used is high carbon steel.Properties of high carbon steel• Carbon content is over 0.8% and less than 2.11%.• It has a reputation for being hard, but the extra carbon makes it brittle than other type of steel.• Carbon found in this metal usually falls around 1.5%.

The chemical composition of the High carbon steel is shown in the Table

Table .1 Chemical composition of high Carbon steel

Properties Chemical composition (%)

C 0.55-0.95Mn 0.30-0.90P Max. 0.04S Max. 0.05Si 0.15-0.35

Page 26: laboratory report on manufacturing lab -1

Fig. High Carbon steel Machining Process • Grinding of the material is done on surface grinding machine by using

aluminium oxide grinding wheel. The various process parameters of a cylindrical grinding machine include depth of cut, material hardness, work piece speed, grinding wheel grain size, and grinding wheel speed.

• The present takes the following input processes parameters namely depth of cut and aluminium oxide wheel with different grit size. The other parameters are kept constant.

Grinding wheel: Aluminium Oxide (Grit size 80, 120)Feed: ConstantGrinding depth: .1 mm, .2mm,.3mmWork piece: High Carbon SteelWheel speed: 2800 RPM.

The experimental study carried out by using following grinding parameters

Page 27: laboratory report on manufacturing lab -1

• Ra is the arithmetic average of the absolute values of the roughness profile ordinates . It is also called as Arithmetic Average (AA), Centre Line Average (CLA).

• The average roughness is the area between the roughness profile and its mean line, or the integral of the absolute value of the roughness profile height over the evaluation length .

Roughness Average, Ra

Page 28: laboratory report on manufacturing lab -1

• Rz is the arithmetic mean value of the single roughness depths of consecutive sampling lengths. Z is the sum of the height of the highest peaks and the lowest valley depth within a sampling length.

Arithmetic Mean, Rz

Page 29: laboratory report on manufacturing lab -1

Experimental Methodology Conti.......

Fig. Surface grinding operation

Page 30: laboratory report on manufacturing lab -1

Experimental Methodology Conti.......

• Surface roughness measurements were done using MitutoyoSurftest SJ-210type surface test equipment. The length of measurement was selected as 2.5 mm. The equipment must be calibrated for the standard specimen provided. Then the experiment is carried out.

Fig .MitutoyoSurftest SJ-210

Page 31: laboratory report on manufacturing lab -1

Results and Discussions • Surface roughness of the grounded specimen was

measured using the Surftest instrument and the below values for Ra and Rz have been obtained.

Tabular columnTrial No Grit size Depth of

Cut(mm)Ra(μm) Rz (μm)

1 80 0.1 0.61 4.122 80 0.2 0.69 4.343 80 0.3 0.76 4.574 120 0.1 0.48 2.195 120 0.2 0.53 2.276 120 0.3 0.6 2.36

Page 32: laboratory report on manufacturing lab -1

Results Cont.....

• By using the 120 grit aluminium oxide grinding wheel with depth 0.1mm, the obtained Ra and Rz values are found to be minimum. For minimum Ra and Rz values the surface is good.

Fig . Actual Work piece after surface Grinding process

Page 33: laboratory report on manufacturing lab -1

Results Cont.....

• Surface Roughness Ra and Rz (For grit size 80)

Fig 5.2 Roughness vs depth of cutSeries 1-RaSeries 2-Rz

1 2 30.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00

Series1Series2

Page 34: laboratory report on manufacturing lab -1

• Surface Roughness Ra and Rz (For grit size 120)

Fig 5.3 Roughness vs depth of cutSeries 1-RaSeries 2-Rz

• It is concluded from the above graphs that Ra value decreases with the increase in depth of cut. Similarly Rz value decreases with increase in depth of cut.

1 2 30.000.501.001.502.002.503.003.504.004.505.00

Series1Series2

Page 35: laboratory report on manufacturing lab -1

Conclusions• With this experiment, we conclude that surface roughness of

the grounded surface is inversely proportional to the grit size (roughness value increases with the decrease in grit size value).

• Surface roughness of the component increases with the increase in depth of cut i.e. depth of cut should be minimum to obtain smooth surface.

Page 36: laboratory report on manufacturing lab -1

REFERENCES

1. R. R. Chakule et al.‘Optimization of Cutting Parameters and Grinding Process for Surface Roughness using Taguchi Method band CFD Analysis’ International Journal of Research in Advent Technology, Vol.3, No.7,pp 23-30, July 2015.

2. Balwinder Singh et al. ‘Effect of Process Parameters on Surface Roughness of Mild Steel Processed by Surface Grinding Process’ AJEAT Vol.1 No.2, pp 1-4, July - December 2012.

3. M.Melwin Jagadeesh Sridhar et al. ‘Optimization of Cylindrical Grinding Process Parameters of OHNS Steel Rounds Using Design of Experiments Concept’ International Journal of Engineering Trends and Technology, Vol. 17 No. 3, pp 109-114, Nov 2014.

4. Lijohn P George et al. ‘Study on Surface Roughness and its Prediction in Cylindrical Grinding Process based on Taguchi method of optimization’ International Journal of Scientific and Research Publications, Vol. 3, Issue 5, pp 1-5, May 2013.

5. Pawan Kumar et al. ‘Optimization of Process Parameters in Surface Grinding Using Response Surface Methodology’ IJRMET Vol. 3, Issue 2,pp 245-252 May - Oct 2013.

6. Module 5 Abrasive Processes (Grinding) Version 2 ME, IIT Kharagpur.7. Abd faiz bin muhammad ‘effect of abrasive tools on surface finishing when grinding

mild steel’ University malaysia pahang.

Page 37: laboratory report on manufacturing lab -1

THANK YOU