Abstract
This research paper depicts the process of used liquid nitrogen at the interface of TiN coated carbide cutting tool insert (rake face) and AISI D3 workpiece. Design of experiments (DoE) was planned according to Taguchi L9 (OA) orthogonal array. The experimental results during machining such as cutting force, machining time and temperature were optimized by Taguchi S/N ratio and analysed by ANOVA. The contribution of machining parameters of (i) speed, (ii) feed and (iii) depth of cut for each response were evaluated. Feed had the highest effect on the percentage of contribution of 57.21% and 52.21% for cutting force and machining time, respectively. Speed had the highest effect on the contribution as 79.57% for the temperature at the interface of insert and workpiece. The predicted values at the optimum level of machining parameters for cutting force, machining time and temperature were 44.49 N, 37.09 sec. and 24.99°C, respectively. Regression models were made. The R-Sq values were 96.59, 89.34 and 96.09% for cutting force, machining time and temperature, respectively. The ratio of an average thickness of generated chip and feed was considered as the chip compression ratio. It was observed that the generated chips during cryogenic turning were thin, discontinuous, long snarled and most of the material had side flow on either side.
Similar content being viewed by others
Abbreviations
- Ct′:
-
Cutting Force during cryogenic turning with LN2
- Mt′:
-
Machining time during cryogenic turning with LN2
- Tc′:
-
Temperature during cryogenic turning with LN2
- Vd′:
-
Speed (m/min.)
- Fd′:
-
feed (mm/rev.)
- Dt′:
-
Depth of cut (mm)
- λ′:
-
Inclination angle
- α′:
-
Orthogonal rake angle
- β′:
-
Orthogonal clearance angle of principal flank
- γ′:
-
Auxiliary orthogonal clearance angle
- φ′:
-
Auxiliary cutting edge angle
- θ′:
-
Principal cutting edge angle
- r′:
-
Nose radius (mm)
- OA:
-
Orthogonal array
- DoE:
-
Design of Experiment
- LN2 :
-
Liquid Nitrogen
- CO2 :
-
Frozen Carbon dioxide
- AD:
-
Anderson-Darling value
References
Byrne G and Scholta E 1993 Environmentaly clean machining processes - a strategic approach. CRIP Ann. Manuf. Technol. 42(1): 471–474
Shokrani A, Dhokia V and Newman S T 2012 Environmentally conscious machining of difficult-to- machine materials with regard to cutting fluids. Int. J. Mach. Tools Manuf. 57: 83–101
Pereira O, Rodriguez A, Fernandez-A A I, Barreiro and Lopezde L N 2016 Cryogenic and minimum quantity lubrication for eco-friendly turning of AISI 304. J. Clean Prod. 139: 440–449
Hong S Y and Broomer M 2000 Economical and ecological cryogenic machining of AISI 304 austenitic stainless steel. Clean Technol. Environ. Policy 2(3): 157–166
Boubekri N and Foster P R 2015 A technology enabler for green machining: minimum quantity lubrication (MQL). J. Manuf. Manag. 212(5): 556–566
Pusavec F, Kramar D, Krajnik P and Kopac J 2010 Transitioning to sustainable production-Part-II: Evaluation of sustainable machining technologies. J. Clean Prod. 118(12): 1211–1221
Debnath S, Reddy M M and Yi Q S 2014 Environmental friendly cutting fluids and cooling techniques in machining: A review. J. Clean Prod. 83: 33–47
Liew P J, Shaaroni A, Sidik N A C and Yan J 2017 An Overview of current status of cutting fluids and cooling techniques of turning hard steel. Int. J. Heat Mass Transf. 114: 380–394
Hong S Y and Zaho Z 1999 Thermal aspects, material considerations and cooling strategies in cryogenic machining. Clean Prod. Process. 1: 107–116
Yang W H and Tarang Y S 1998 Design optimization of cutting parameters for turning based on Taguchi method. J. Mater. Process. Technol. 84: 122–129
Mia M 2017 Multi-response optimization of end milling parameters under through-tool cryogenic cooling condition. Measurement 111:134–145
Chinchanikar S and Choudhary S K 2015 Machining of hardened steel—Experimental investigations, performance modelling and cooling techniques: A review. Int. J. Mach. Tools Manuf. 89: 95–109
Sharma V S, Dogra M and Suri N M 2009 Cooling techniques for improved productivity in turning. Int. J. Mach. Tool Manuf. 49: 435–453
Yildiz Y and Nalbant M 2008 A review of cryogenic cooling in machining processes. Int. J. Mach. Tools Manuf. 48: 947–964
Manimaran G, Kumar M P and Venkatasamy R 2014 Influence of cryogenic cooling on surface grinding. Cryogenics 59: 76–83
Manimaran G and Kumar M. Pradeep 2013 Effect of cryogenic cooling and sol-gel alumina wheel on grinding performance of AISI 316 stainless steel. Arch. Civ. Mech. Eng. 13: 304–312
Dhananchnezian M and Kumar M P 2011 Cryogenic turning of the Ti-6Al-4V alloy with modified cutting tool inserts. Cryogenics 51: 34–40
Sartori S, Ghiotti A and Bruschi S 2017 Hybrid lubricating/cooling strategies to reduce the tool wear in finishing turning of difficult-to-cut alloys. Wear 376–377: 107–114
Hong S Y and Ding Y 2001 Cooling approaches and cutting temperatures in cryogenic machining of Ti-6Al-4V. Int. J. Mach. Tools Manuf. 41(10): 1417–1437
Hong S Y, Dong Y and Jeong W 2001 Friction and cutting forces in cryogenic machining of Ti-6Al-4V. Int. J. Mach. Tools Manuf. 41(15): 2271–2285
Hong S Y, Markus I and Jeong W 2001 New cooling approach and tool life improvement in cryogenic machining of titanium alloy. Int. J. Mach. Tools Manuf. 41(15): 2245–2260
Dhar N R, Paul S and Chattopadhyay A B 2002 The influence of cryogenic cooling on tool wear, dimensional accuracy and surface finish in turning AISI 1040 and E4340C steels. Wear 249: 932–942
Dhar N R, Paul S and Chattopadhyay A B 2002 Machining of AISI 4140 steel under cryogenic cooling—toolwear, surfaceroughness and dimensional deviation. J. Mater. Process. Technol. 123: 483–489
Dhar N R and Kamruzzaman M 2007 Cutting temperature, tool wear, surface roughness and dimensional deviation in turning AISI-4037 steel under cryogenic condition. Int. J. Mach. Tools Manuf. 47: 754–759
Dhar N R, Nand Kishore S V, Paul S and Chattopadhay A B 2002 Effects of cryogenic cooling on chips and cutting forces in turning AISI 1040 and 4320 steel. Proc. IMeche Part B J. Eng. Manuf. 216: 713–724
Bermingham M J, Kirsch J, Sun S, Palanisamy S, Dargusch M S 2011 New observations on tool life, cutting forces and chip morphology in cryogenic machining Ti6AL4V. Int. J. Mach. Tools Manuf. 51: 500–511
Diniz A E, Machado A R and Correa J G 2016 Tool wear mechanisms in the machining of steels and stainless steels. Int. J. Adv. Manuf. Technol. 87: 3157–3168
Strano M, Chiappini E, Tirelli S, Albertelli P and Monno Michele 2013 Comparison of Ti6Al4 V machining forces and tool life for cryogenic versus conventional cooling. Proc. IMechE Part B J. Eng. Manuf. 227(9): 1403–1408
Venugopal K A, Tawade R, Prashanth P G, Paul S and Chattopadhyay A B 2003 Turning of titanium alloy with TiB2-coated carbides under cryogenic cooling. Proc. IMechE Part B J. Eng. Manuf. 217: 1697–1707
Sun S, Brandt M and Dargush M S 2010 Machining Ti-6Al-4V alloy with cryogenic compressed air cooling. Int. J. Mach. Tools Manuf. 50: 933–942
Mia M and Dhar N R 2017 Influence of single and dual cryogenic jets on machinability characteristics in turning of Ti-6Al-4V. Proc. IMechE Part B J. Eng. Manuf. 1–16
Khan A and Maity K 2017 Comparative study of some machinability aspects in turning of pure titanium with untreated and cryogenically treated carbide inserts. J. Manuf. Process. 28: 272–284
Chetan, Ghosh S and Rao P V 2017 Performance evaluation of deep cryogenic processed carbide inserts during dry turning of Nimonic 90 aerospace grade alloy. Tribol. Int. 115: 397–408
Lal D M, Renganarayanan S and Kalanidhi A 2001 Cryogenic treatment to augment wear resistance of tool and die steels. Cryogenics 41: 149–155
Shokarani A, Dhokia V and Newman S T 2016 Energy conscious cryogenic machining of Ti-6Al-4v titanium alloy. Proc. IMechE Part B J. Eng. Manuf. 232(10): 1690–1706
Aggarwal A, Singh H, Kumar P and Singh M 2008 Optimization of multiple quality characteristics for CNC turning under cryogenic cutting environment using desirability function. J. Mater. Process. Technol. 205: 42–50
Yilmaz B, Karabulut S and Gullu A 2018 Performance of analysis of new chip breaker for efficient machining of Inconel 718 and optimization of the cutting parameters. J. Manuf. Process. 32: 553–563
Kalyan K K V B S and Choudhury S K 2008 Investigation of tool wear and cutting force in cryogenic machining using design of experiments. J. Mater. Process. Technol. 203: 95–101
Viswanathan R, Ramesh S and Subburam V 2018 Measurement and optimization of performance characteristics in turning of Mg alloy under dry and MQL conditions. Measurement 120: 107–113
Gupta M K and Sood P K 2016 Optimizing multi-characteristics in machining of AISI 4340 steel using Taguchi’s approach and utility concept. J. Inst. Eng. (India) Ser. C. 97(1): 63–69
Dureja J S, Singh R and Bhatt M S 2014 Optimization flank wear and surface roughness during hard turning of AISI D3 steel by Taguchi and RSM methods. Prod. Manuf. Res. 2: 767–783
Mandal N, Doloi B and Mondal B 2016 Surface roughness predication model using zirconica toughned aluminia (ZTA): Taguchi method and regression analysis. J. Inst. Eng. (India) Ser. C. 97(1): 77–84
Kumar Dr V, Kiran K B J and Rudresha N 2018 Optimization of machining parameters in CNC turning of stainless steel (EN19) by Taguchi’s orthogonal array experiments. Mater. Today Proc. 5: 11395–11407
Mozammel M M, Prithbey, Dey R, Hossain M S, Arafat S M T, Asaduzzaman Md, Ullah Md. S and Zobaer S M T 2018 Taguchi S/N based optimization of machining parameters for surface roughness, too wear and material removal rate in hard turning under MQL cutting condition. Measurement 122: 380–391
Gunay M and Yucel E 2013 Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron. Measurement 46: 913–919
Durakbasa M N, Akdogan A, Vanil A S and Bulutsuz A G 2015 Optimization of end milling parameters and determination of the effects of edge profile for high surface quality of AISI H13 steel by using precise and fast measurements. Measurement 68: 92–99
Rath D, Panda S and Pal K 2018 Prediction of surface quality using chip morphology with nodal temperature signatures in hard turning of AISI D3. Mater. Today 5: 12368–12375
Zerti O, Yallease M A, Khettabi R, Chaoui K and Marbrouki T 2017 Design optimization for minimum technological parameters when dry turning of AISI D3 steel using Taguchi method. Int. J. Adv. Manuf. Technol. 89: 1915–1934
Hasclik A and Caydas U 2008 Optimization of turning parameters for surface roughness and tool life based on Taguchi method. Int. J. Adv. Manuf. Technol. 38: 896–903
Mandal N, Doloi B, Mondal B and Das R 2011 Optimization of flank wear using Zirconia toughned aluminia (ZTA) cutting tool: Taguchi method and Regression analysis. Measurement 44: 2129–2155
Shokrani A, Dhokia V and Newman S T 2016 Investigation of the effects of cryogenic machining on surface integrity in CNC end milling of Ti-6Al-4 V titanium alloy. J. Manuf. Process. 21: 172–179
Thirumalai R, Senthilkumar J S, Selvarani P and Ramesh S 2012 Machining characteristics of Inconel 718 under several cutting conditions based on Taguchi method. Proc. IMeche Part C J. Mech. Eng. Sci. 227(9): 1889–1897
Fredj N, Habibsidhon and Braham C 2006 Ground surface improvements of the austentic stainless steel AISI 304 using cryogenic cooling. Surf. Coat. Technol. 200: 4846–4860
Sivaiah P and Charkardha D 2018 A comparison with MQL, wet, dry machining. CIRP J. Manuf. Sci. Technol. 21: 86–96
Zebia W and Kowlczyk R 2015 Estimating the effect of cutting data on surface roughness and cutting force during WC-CO turning with PCD tool using Taguchi design and ANOVA analysis. Int. J. Adv. Manuf. Technol. 77: 2241–2256
Ross P J 1996 Taguchi Techniques for quality engineering. New York: McGraw-Hill: pp. 181–196
Mohanty SD, Mahapatra SS and Mohanty R C 2019 PCA based hybrid Taguchi philosophy for optimization of multiple responses in EDM. Sadhna 44(2):1–9 https://doi.org/10.1007/s12046-018-0982-z
Ghodsiyeh D, Akbarzadeh S, Izman S and Morad M 2019 Experimental investigation of surface integrity after wire electro-discharge machining of Ti-6Al-4V. Sadhna 44(196): 1–15 https://doi.org/10.1007/s12046-019-1184-z123456789
Acknowledgements
Authors are thankful to the workshop and laboratories facilities shared by Delhi Technological University and Indian Institute of Technology, Delhi (India).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Sharma, A., Singh, R.C. & Singari, R.M. Optimization of machining parameters during cryogenic turning of AISI D3 steel. Sādhanā 45, 124 (2020). https://doi.org/10.1007/s12046-020-01368-4
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12046-020-01368-4