International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 2, March - April (2013), pp. 392-400 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

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COMPARISON OF PERFORMANCE OF COATED CARBIDE INSERTS WITH UNCOATED CARBIDE INSERTS IN TURNING GRAY CAST IRON
Yuvaraj P. Ballal1, Manjit M. Khade2, Ajit R. Mane3
1 2

(Department of Mechanical Engineering, ADCET, Ashta,India) (Department of Mechanical Engineering, ADCET, Ashta,India ) 3 (Department of Mechanical Engineering, ADCET, Ashta,India)

ABSTRACT In this study, machining performance of a series of commercially available coated tungsten carbide inserts were investigated during turning of gray cast iron brake drum. The inserts tested had a coating of TiCN and TiAlN respectively. For comparison, uncoated cemented tungsten carbide insert of K10 grade was also tested under the same cutting conditions. Taguchi analysis using ANOVA for 3 parameter, 3 level experimentation - full factorial (L27 array) were done with output response variables like surface roughness, material removal rate, tool wear. Main effects of factors and their interactions were studied. Keywords: ANOVA, Cemented tungsten carbide insert, Coating, Gray cast iron, Machining performance, Taguchi analysis. 1. INTRODUCTION The challenge of modern machining industries is mainly focused on the achievement of high quality, in terms of work piece surface finish, high production rate, less wear on the cutting tools, economy of machining in terms of cost saving and increase the performance of the product[1]. Effective machining of work material depends upon the selection of appropriate cutting tool. A wide range of cutting tool materials is available with variety of properties, performance capabilities, and cost. These include high speed steels, cemented carbides, ceramics, cermets, cubic boron nitride, and diamond. The cutting tool material, cutting parameters and tool geometry directly influence the productivity of machining operation [2].
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME 2. EXPERIMENTAL DETAILS 2.1. Selection of work and tool material Gray iron is one of the oldest cast ferrous products. In spite of competition from newer materials and their energetic promotion, gray iron is still used for those applications where its properties have proved it to be the most suitable material available. Gray iron castings are readily available in nearly all industrial areas and can be produced in foundries representing comparatively less investments. Chemical composition of FG260 gray cast iron is shown in following table 1. The recently developed tool materials like coated carbides have improved the productivity levels of difficult-to-machine materials. The coated carbide tool was selected for turning of cast iron. Cemented carbide is chosen as uncoated cutting tool material. The ISO grade selected is K10. Other details are: Designation : CNMA 120408 Nose radius : 0.8 mm Tool Holder : PCLNR 2525 M 12. Table 1: Chemical composition of gray cast iron
Elements Carbon Silicon Manganese Sulphur Phosphorous Iron Composition % 2.5 -3.7 0.10-0.30 0.5-1.0 0.07-0.1 0.1-0.9 remainder

2.2. Selection of work and tool material In Taguchi method-based design of experiments, to select an appropriate orthogonal array for experimentation, the total degrees of freedom (DOF) needs to be computed. The DOF is defined as the number of comparisons between machining parameters that need to be made to determine, which level is better and specifically how much better it is. For example, a three-level machining parameter has two DOF. The DOF associated with interaction between two machining parameters are given by the product of the DOF for the two machining parameters. In the present study, interactions between the three machining parameters will be considered. Therefore, there are 18 DOF owing to three three-level independent parameters, refer table 2 [3].

Table 1: Machining parameters and their levels

Process Parameters Cutting speed (mm/min) Feed (mm/rev) Tool type Parameter Designation A B C DOF 2 2 2 [(3-1) X (31)] X 3=12 18 I 350 0.2 Uncoated K10 carbide insert Levels II 400 0.25 TiCN coated K10 carbide insert III 450 0.3 TiAlN coated K10 carbide insert -

Interactions (AB,AC, BC) Total DOF

The machine used for turning is SIMPLE TURN 5075 CNC LATHE (Fanuc Series).
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

2.3. Experimental results The experimental results obtained after performing experiments are shown in the table 3[3,4]. Table 3: Experimental results
St. order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Cutting speed m/min 350 350 350 350 350 350 350 350 350 400 400 400 400 400 400 400 400 400 450 450 450 450 450 450 450 450 450 Feed mm/rev 0.2 0.2 0.2 0.25 0.25 0.25 0.3 0.3 0.3 0.2 0.2 0.2 0.25 0.25 0.25 0.3 0.3 0.3 0.2 0.2 0.2 0.25 0.25 0.25 0.3 0.3 0.3 Tool type UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN UC TiCN TiAlN Depth of cut (mm) (const.) 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Surface finish(Ra) ( m) 2.08 3.52 1.03 2.86 4.23 1.82 3.26 5.38 2.38 1.80 3.28 2.20 1.38 2.62 3.93 3.08 5.48 2.46 1.89 2.58 4.38 2.42 5.28 3.35 3.58 4.83 4.68 Tool wear rate (gms/min) 0.00125 0.00021 0.00006 0.00182 0.00017 0.00012 0.00224 0.00034 0.00008 0.00240 0.00020 0.00003 0.00260 0.00024 0.00003 0.00326 0.00030 0.00038 0.00302 0.00004 0.00008 0.00602 0.00006 0.00019 0.00436 0.00138 0.00014 Flank wear (mm) 0.513 0.096 0.024 0.972 0.062 0.034 0.920 0.098 0.028 1.087 0.092 0.017 0.966 0.094 0.014 1.130 0.126 0.143 1.184 0.023 0.032 1.820 0.038 0.064 1.540 0.532 0.056 MRR

242.214 300.775 372.235 288.315 340.153 420.857 316.123 418.192 436.324 304.278 315.441 406.451 308.970 413.397 543.157 324.671 469.148 568.420 343.210 497.435 582.690 401.238 714.000 879.545 447.058 865.116 998.120

3. STATISTICAL ANALYSIS OF VARIANCE The statistical analysis of variance for all responses is as follows [1, 2, 3, 4, 5, and 6], 3.1. Statistical Analysis of Surface Roughness (Ra) Statistical ANOVA shown in Table 4, indicate that tool type is the most significant factor for surface roughness which has P-value of 0.002.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Table 4: ANOVA for Surface finish (Ra) Source Cutting speed Feed rate Tool type Error Total DF 2 2 2 20 26 SS 3.2278 8.5834 13.1821 15.9178 40.9112 MS 1.6139 4.2917 6.5911 0.7959 F 2.03 5.39 8.28 P 0.158 0.013 0.002 -

S=0.892127

R-Sq= 61.09 % R-Sq(adj) = 49.42 % SS= sum of squares

The main effect plot (Fig.1) shows that cutting speed has almost no effect on the surface roughness at higher levels. Feed rate has linear relationship with the surface roughness, it increases as feed rate is increased due to the fact that more forces of the tool on the workpiece due to higher feed rates tends to lose the surface finish, so for good surface quality, a low feed rate is essential. Uncoated tools exhibit lower surface roughness than coated tools, this is due to loss of tool edge at continuous machining by uncoated tools.
Data Means
cutting speed 4.0 3.5 3.0 feed

Mean

2.5 350 4.0 3.5 3.0 2.5 UC TiCN TiAlN 400 tool type 450 0.20 0.25 0.30

Fig 1. Main effect plot for Surface finish (Ra) The interaction plot as shown in Fig 2, indicates that at higher speeds and higher feeds, the surface roughness increases and this is same for both coated and uncoated tools. Surface roughness values decreases as speeds increases from 350 to 450 m/min in comparison to both coated and uncoated tools.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Fig 2. Interaction plot for surface finish 3.2. Statistical Analysis of Tool Flank Wear It is found that the tool wear progresses rapidly during machining of cast iron. Statistical ANOVA shows that the tool type is the most significant factor for the wear and cutting speed is the next influencing factor(refer table 5). Table 5: ANOVA for tool flank wear Source Cutting speed Feed rate Tool type Error Total DF 2 2 2 20 26 SS 0.3680 0.1302 6.5007 0.8311 7.8300 MS 0.1840 0.0651 3.2503 0.0416 F 4.43 1.57 78.21 P 0.026 0.233 0.000 -

S = 0.203854 R-Sq = 89.39% R-Sq(adj) = 86.20% The main effects plots (Fig 3) shows that an increase in cutting speed causes rapid increase in the tool wear.Feed rate shows very linear effect on the wear. As feed is increased, there is more increment in the wear since feed rate increases with increase in force on cutting edge of tool. Uncoated tools have higher wear as compared to coated tools, the least wear is observed in TiAlN coating as shown in Fig 3.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Main Effects Plot for flank wear (mm)

Data Means
cutting speed 1.00 0.75 0.50 0.25 feed

Mean

0.00 350 400 tool type 450 0.20 0.25 0.30

1.00 0.75 0.50 0.25 0.00 UC TiCN TiAlN

Fig 3. Main effect plot for tool flank wear (mm) The wear behavior at the lower to higher speeds is almost the same at different feed rates, as seen in Fig 4. At lower feed of 0.2 mm/rev, the wear is least. Uncoated tools exhibiting higher flank wear than coated tools. It is also seen that as speed is increasing, the flank wear is also increasing, this is due to the loss of hot hardness at high cutting speed. All the tools exhibit higher flank wear at higher feeds.

Fig 4. Interaction plot for tool flank wear

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

3.3. Statistical Analysis of Material Removal Rate Statistical ANOVA shown in Table 6, indicate that in case of MRR, all process parameters namely cutting speed, feed and tool type are significant factors. Table 6: ANOVA for MRR Source Cutting speed Feed rate Tool type Error Total DF 2 2 2 20 26 SS 418421 124567 281027 162503 986518 MS 209211 62283 140514 8125 F 25.75 7.67 17.29 P 0.000 0.003 0.000 -

S = 90.1397 R-Sq = 83.53% R-Sq(adj) = 78.59

Fig 5. Main effect plot for MRR (gm/min) The main effects plots (Fig 5) and interaction plots (Fig 6) shows that MRR increases with increase in cutting speed, feed and tool type and most significant at 450 m/min, 0.3 mm/rev and TiAlN coated cutting tool.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME

Fig 6. Interaction plot for MRR

4. CONCLUSION The experiments were conducted as per Taguchi L 27 orthogonal array. After fixing process parameters (cutting speed, feed, depth of cut and cutting tool material) observations for response variables (SF, Tool wear, MRR) were taken. The following are the conclusions made after experimentation and statistical analysis of variance. 1. Tool type is the most significant factor for surface roughness. Coated cutting tools shows higher roughness values than uncoated cutting tools at lower feed rates and roughness value increased as feed rate increased. 2. The roughness value for TiAlN coated cutting tools increases with increase in cutting speed and roughness value for TiCN is high and roughness value for uncoated cutting tools is low for selected cutting speed range. 3. Tool wear rate is much higher for uncoated cutting tool than coated cutting tools for selected process parameters. For TiAlN coated cutting tool have least tool wear. 4. MRR increases with increase in cutting speed , feed and most significant at 450 m/min, 0.3 mm/rev and TiAlN coated cutting tool. REFERENCES

[1] Thamizhmanii S., Saparudin S. and Hasan S. Analyses of surface roughness by turning
process using Taguchi method, Journal of achievements in material and manufacturing engineering, Pg. 503-506, Vol. 20, Issue 1-2, Jan- Feb, 2007 [2] Khandey Umesh, Optimization of surface roughness, material removal rate and cutting tool flank wear in turning using extended Taguchi approach, masters dissertation report, NIT Rourkela, August 2009.
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[3] Ramji B.R, H.N. Narasimha Murthy and M. Krishna, Analysis of roughness and flank
wear in turning gray cast iron using cryogenically treated cutting tools, Research Journal of Applied Sciences, Engineering and Technology 2(5), Pg. 414-417, 2010, ISSN: 20407467 [4] Gopalsamy Bala Murugan, Mondal Biswanath and Ghosh Sukamal, Taguchi method and ANOVA: An approach for process parameters optimization of hard machining while machining hardened steel, Journal of Scientific and Industrial Research, Vol. 8, August 2009, pp. 686-695. [5] Dolinek S. and Kopa J., Mechanism and types of tool wear particularities in advanced cutting materials, Journal of Achievements in Materials and Manufacturing Engineering, November 2006, Volume 19 Issue 1. [6] Singh Hari, Optimizing Tool Life of Carbide Inserts for Turned Parts using Taguchis Design of Experiments Approach, Proceedings of the International MultiConference of Engineers and Computer Scientists 2008 Vol II, 19-21 March, 2008. [7] K.Dharma Reddy and Dr.P.Venkataramaiah, Experimental Investigation on Responses in Turning of Aluminium with Carbide Tipped Tool at Different Coolant Conditions International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 189 - 199, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [8] R. R. Deshmukh and V. R. Kagade, Optimization of Surface Roughness in Turning High Carbon High Chromium Steel by using Taguchi Method, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 1, 2012, pp. 321 - 331, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [9] Vipin Kumar Sharma, Qasim Murtaza and S.K. Garg, Response Surface Methodology & Taguchi Techquines to Optimization of C.N.C. Turning Process, International Journal of Production Technology and Management (IJPTM), Volume 1, Issue 1, 2010, pp. 13 - 31, ISSN Print: 0976- 6383, ISSN Online: 0976 6391.

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