Optimization of Turning Process Parameters for Mild Steel

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 11, 2016 | ISSN (online): 2321-0613

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Optimization of Turning Process Parameters for Mild Steel Prof. Alpesh R. Patel1 Prof. Lalit S. Patel2 Prof. Tejas C. Patel3

1,3Assistant Professor 2Research Scholar 1Government Engineering College, Valsad, Gujarat, India

2Rai University, Ahmedabad, Gujarat, India 3Shree Swami Atmanand Saraswati Institute of Technology, Surat, Gujarat, India

Abstract— The present research paper is focused on the

analysis of optimum cutting conditions to get lowest cutting

forces in turning of mild steel material. The experimental

result analysis showed that the optimum combination of

various input factors as type of insert type, work piece

material, Approach Angle, feed and depth of cut. Further,

the confirmation tests are conducted and the results are

found to be increased with increment of feed and depth of

cut.

Key words: Turning, Mild Steel, Lathe Machine, Cutting

Forces, Optimization

I. INTRODUCTION

This project is on the analysis of the effect in change of

different parameters in turning process. The various

parameters that are important in turning are,

A. Machining Feed:

There are different feeds available on the lathe machine,

which are varied to determine the effect of feed on the

cutting forces.

B. Depth of Cut:

The depth of cut can be varied with the help of micrometer

dial on the cross-slide.

C. Approach Angle:

Different approach angles will be taken for the analysis.

Other tool geometry will be kept constant.

Tool material will also be kept same.

II. MACHINES/ INSTRUMENTS REQUIRED

The details of machines and equipment available in

workshop on which the project will be carried out are given

below:

A. Lathe Machine:

Fig. 1: Lathe Machine

Type Range of speeds (RPM) Range of feed Main motor Table feed motor(hp)

HMT Lathe 32,52,88,150,250,420

710,1200

[0.05,0.06,0.07,0.10,0.13,0.15]

[0.20,0.26,0.30,0.40,0.52,0.6]

[0.83,1.04,1.25,1.65,2.08,2.5]

2 1

Table 1: Lathe Machine

B. Dynamometer:

For the measurement of cutting forces a three component

strain gauge type lathe tool dynamometer is used for the

present work. It consists of orthogonal ring and used to

measure force values in three directions, one vertical

direction two force components in longitude and transverse

direction. The assembly consists of four octagonal rings

arranged at right angles to each other and strain gauges

which are fixed between two thick plates. Range of force

measurement is 0-500 kg in all directions. Two rings are

used to measure forces in feed direction and the other two in

axial direction and all the four rings for the vertical

component of cutting force. All the rings are identical in

shape and can measure forces in three mutual perpendicular

directions

The Dynamometer is divided into the following

subunits. Sensing unit: the sensing unit consists of four

orthogonal rings with strain gauges cemented on arms. The

unit accurately senses forces in three axes to the bridge

circuit. Bridge balancing unit: The bridge balancing unit

consists of power supply used to supply power to three

bridge circuits. Measuring unit: A standard DC motors are

provided to measure the output of the bridge unit directions

in terms of kg. Some instructions are necessary for bridge

balancing unit before performing the operations.

Fig. 2: Sharp Dynamometer (Strain Gauge)

The sensing unit of dynamometer should be in

proper position on the lathe machine tool post. With help of

Optimization of Turning Process Parameters for Mild Steel

(IJSRD/Vol. 3/Issue 11/2016/021)


cables, carefully connect PUI socket on the sensing unit to

the PUI socket on the strain gauge amplifier unit. Similar

connections were made for PU2 channel and PU3 channel.

The instrument is made connected to 230 Volts single phase

supply. Dynamometer tool holder top view (tool attached).

After all the necessary precautions taken measurement setup

was kept ready for the experiment purpose. Align the

dynamometer with the lathe machine tool post and clamp it

to the T-slots present in the table. Set machine for the

automatic feed. Connect the input cable between the socket

marked PUI on dynamometer unit and the socket marked

PUI on the display unit (bridge balance unit). Similar

connections were made for PU2 and PU3 channels. Zero

adjustment is being made before taking any reading. Supply

the power through main by operating switch and the setup is

ready for the measurement of cutting forces on lathe

machine. Precautions in force measurement: Following

precautions should be taken during the experiment. Socket

connections were done very carefully. There should not be

any excessive loads on sensing unit. The balance posts are

operated carefully. Before taking next reading the bridge

should be in balanced condition. After the experiments

switch-off the AC mains. The cables were removed properly

from socket.

III. WORKPIECE AND TOOL MATERIAL SELECTION

The work piece material is Mild steel bar with length of 2

feet and the diameter 50 mm.

Strength of the work piece material is as follows:

Mild steel: 550 N/mm2 Tool material is HSS (High Speed

Steel).

Mild steel can be machined for turning process

with the cutting speeds available on the given lathe machine.

High Speed Steel exhibits a density of 8.67x1000 kg/m3

(kilograms per meters-cubed). This high density affords it

incredible durability and hardness (even at high

temperatures) and shock and vibration resistance while still

allowing for its machinability into tools and drill bits.

A. Tool Grinding:

HSS tool bits procured from workshop were ground on the

rough grinding machine. The speed of grinding machine was

1500 RPM. The tool geometry as taken from PSG design

data book for work piece material as mild steel and tool

material HSS are:

Back Rake Angle: 110

Side Rake Angle: 110

End Relief Angle: 90

Side Relief Angle: 90

The different approach angles taken on five tools

were 700, 750, 800, 850, 900.

Fig. 2: Approach angle 900 and 850.

Fig. 3: Approach angle 800, 750, 700

IV. EXPERIMENTAL OBSERVATIONS

Diameter of Mild Steel Bar: 46.5 mm

RPM: 250

No. Input Parameters Output Data

App.

Angle

Feed

(mm/rev)

Depth of

Cut

(mm)

Fx

(kgf)

Fy

(kgf)

Fr

(kgf)

1 70 0.05 0.5 17.7 10 -1.8

2 70 0.05 1 33.3 24.6 -0.5

3 70 0.05 1.5 44 40.1 1.6

4 70 0.05 2 62.8 52 4.2

5 70 0.05 2.5 76.5 72.4 5.9

6 70 0.06 0.5 20.9 15.1 0.6

7 70 0.06 1 35.7 29.8 2.4

8 70 0.06 1.5 49 47.4 4.9

9 70 0.06 2 72.1 62.5 8.1

10 70 0.06 2.5 85.3 74.5 13.2

11 70 0.07 0.5 19.1 17 -0.3

12 70 0.07 1 40.9 37.2 2.1

13 70 0.07 1.5 59 54.3 4.2

14 70 0.07 2 73.3 69.1 8.2

15 70 0.07 2.5 88.5 84.9 12.4

16 70 0.1 0.5 21.8 22.4 -1.4

17 70 0.1 1 46.2 46.8 1.2

18 70 0.1 1.5 68.2 62.6 5.4

19 70 0.1 2 86 66.2 11.3

20 70 0.1 2.5 105.9 100.4 16.2

21 70 0.13 0.5 37 30.9 -2.6

22 70 0.13 1 61 58.6 1.6

23 70 0.13 1.5 83.3 82.4 5.8

24 70 0.13 2 100.2 104.3 10.2

25 70 0.13 2.5 113.1 120.5 19.3

26 75 0.05 0.5 14.6 7.9 0.2

27 75 0.05 1 30.4 21.3 2.2

28 75 0.05 1.5 44.5 33.2 4.4

29 75 0.05 2 59.8 42.3 8.7

30 75 0.05 2.5 66.9 58.1 11.6

31 75 0.06 0.5 10.8 13.5 1.2

32 75 0.06 1 28.3 26.9 3.4

33 75 0.06 1.5 44 42.4 6.1




34 75 0.06 2 57.6 53.1 10.2

35 75 0.06 2.5 67.8 62.3 13.1

36 75 0.07 0.5 24.3 12.5 1.8

37 75 0.07 1 44.3 30 5.8

38 75 0.07 1.5 61.2 45.5 8.2

39 75 0.07 2 71.5 56.8 12.7

40 75 0.07 2.5 86.1 66.7 16.3

41 75 0.1 0.5 27.1 16.9 -0.4

42 75 0.1 1 51.3 38.5 4.2

43 75 0.1 1.5 70.2 58.7 8.5

44 75 0.1 2 88.9 74.3 13.4

45 75 0.1 2.5 102.1 92.9 19.7

46 75 0.13 0.5 25.9 19.6 0.5

47 75 0.13 1 56.8 44.6 4.6

48 75 0.13 1.5 80.1 67.3 10

49 75 0.13 2 99.1 87.3 15.9

50 75 0.13 2.5 115.9 114.3 25.1

51 80 0.05 0.5 22.2 16.1 1.5

52 80 0.05 1 38.4 30 3.4

53 80 0.05 1.5 52.4 42.9 6.4

54 80 0.05 2 65.4 52 8.7

55 80 0.05 2.5 78 65.2 12.9

56 80 0.06 0.5 21 17.3 2.9

57 80 0.06 1 37.8 32.8 5.7

58 80 0.06 1.5 53.9 47.5 8.3

59 80 0.06 2 65.3 56.4 12.6

60 80 0.06 2.5 75.2 68.3 16.5

61 80 0.07 0.5 21.9 19.2 -0.6

62 80 0.07 1 39.2 36.4 2.8

63 80 0.07 1.5 57.4 50.2 6.6

64 80 0.07 2 69.2 63.3 9.4

65 80 0.07 2.5 85.9 75.2 15.5

66 80 0.1 0.5 23.8 21.1 1.6

67 80 0.1 1 48.6 40.7 4.4

68 80 0.1 1.5 66.9 57.2 7.7

69 80 0.1 2 84.8 77.6 14.9

70 80 0.1 2.5 99.7 92.5 20.2

71 80 0.13 0.5 28.8 24.3 -1.8

72 80 0.13 1 57.8 50.7 2.4

73 80 0.13 1.5 77.5 65.5 5.5

74 80 0.13 2 97.9 92.2 14.3

75 80 0.13 2.5 113.6 108.4 22.2

76 85 0.05 0.5 35.6 19.3 -2.9

77 85 0.05 1 43.8 31.6 7.2

78 85 0.05 1.5 56.7 42.6 11.4

79 85 0.05 2 67.4 54.3 15.8

80 85 0.05 2.5 77.7 65.7 20.3

81 85 0.06 0.5 28.3 22.8 1.1

82 85 0.06 1 49.8 42 3

83 85 0.06 1.5 62.9 53.1 10.9

84 85 0.06 2 75.2 67.7 15.2

85 85 0.06 2.5 87.3 82.4 23.9

86 85 0.07 0.5 31.1 31.2 1.6

87 85 0.07 1 53.6 53.4 4.4

88 85 0.07 1.5 68.7 70.7 8.9

89 85 0.07 2 83.9 81.9 13.8

90 85 0.07 2.5 97.3 101.1 23.7

91 85 0.1 0.5 36.2 34.2 1.1

92 85 0.1 1 64.5 63.9 6.2

93 85 0.1 1.5 79.8 84.3 13.4

94 85 0.1 2 100.9 105.2 21.9

95 85 0.1 2.5 111.7 125.4 22.7

96 85 0.13 0.5 33.7 42.5 -0.3

97 85 0.13 1 60.4 63.3 5.3

98 85 0.13 1.5 86.8 98.3 14.8

99 85 0.13 2 104.7 119.3 24.9

100 85 0.13 2.5 121.4 157.7 39.7

101 90 0.05 0.5 31.8 23.6 10

102 90 0.05 1 54.8 35.3 16.7

103 90 0.05 1.5 67.2 47.6 23.8

104 90 0.05 2 79.4 54.2 29.5

105 90 0.05 2.5 87.6 68.9 27.6

106 90 0.06 0.5 37.8 19.6 8.9

107 90 0.06 1 62.8 39.1 21.8

108 90 0.06 1.5 78.3 53.1 29.7

109 90 0.06 2 93.2 60.8 36.5

110 90 0.06 2.5 97.1 73.4 42.6

111 90 0.07 0.5 38.4 14.7 9.7

112 90 0.07 1 54.7 31.3 16.6

113 90 0.07 1.5 73.8 46.4 27.3

114 90 0.07 2 90.9 61.2 35.6

115 90 0.07 2.5 102.2 74.3 43.2

116 90 0.1 0.5 44.5 21.1 9.1

117 90 0.1 1 69.1 42.9 20.7

118 90 0.1 1.5 91.7 62.3 30.1

119 90 0.1 2 110.9 81.8 41.3

120 90 0.1 2.5 119.1 93.3 54.8

121 90 0.13 0.5 51.9 22.3 10.8

122 90 0.13 1 83.4 54.3 21.9

123 90 0.13 1.5 104.7 70.6 35.1

124 90 0.13 2 124.9 94.6 56.6

125 90 0.13 2.5 132.1 125.1 66.7

Table 2: Experimental Observations




V. GRAPHICAL ANALYSIS AND

A. Representations:

1) Force Vs Feed Graphs:

Fig. 4: Force vs Feed Graphs

Horizontal Force

x-axis = Feed in mm/rev

y- axis = Force in kgf


Vertical Force


y-axiz = Force in kgf


Radial Force


y-axis = Force in kgf


B. Force Vs Depth of Cut Graphs:

Feed = 0.13 mm/rev

x-axis = DOC in mm





Fig. 8: Force Vs Depth of Cut Graphs

FEED = 0.10 mm/rev


x-axis = DOC in mm

Fig. 9: Force Vs Depth of Cut Graphs

VI. FORCE VS DEPTH OF CUT GRAPHS (CONSTANT

APPROACH ANGLE)

Horizontal Force

x-axis = DOC in mm


Fig. 10: Force Vs Depth of Cut Graphs (Constant Approach

Angle)

Vertical Force

x-axis = DOC in mm



Angle)

Radial Force

x-axis = DOC in mm






Angle)

VII. CONCLUSIONS

From the force vs depth of cut graph (at constant angle), it

can be seen that force in all the directions increases with the

increase in feed. From the force vs depth of cut graph (at

constant feed), it can be seen that forces in all directions

increases with increase in approach angle. From the force vs

feed graphs (at constant approach angle), it can be seen that

forces in all directions increase with increase in depth of cut.

Here,

Power= Force x Cutting speed

It can be stated that the power required for cutting

will increase with increase in each of the above three

parameters.

REFERENCES

[1] Ghosh A. and Mallik A. K., "Manufacturing Science",

East West Press, New Delhi, 1998.

[2] Sharma P. C., "A Textbook of Production Engineering",

S. Chand & Company, New Delhi, 2006.

[3] http://en.wikipedia.org/wiki/Turning.

Optimization of Turning Process Parameters for Mild Steel

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