05-07-2013, 03:39 PM
AN INVESTIGATION OF THE EFFECT OF PROCESS PARAMETERS ON MRR IN TURNING OF PURE TITANIUM
AN INVESTIGATION.docx (Size: 126.65 KB / Downloads: 16)
Introduction
The scientists and technologies in the field of manufacturing are facing more and more challenges owing to use of high strength temperature materials especially in the aerospace and automobiles industries. These materials have high strength to weight ratio, high strength, toughness and other improved properties. The high strength, low weight ratio and outstanding corrosion resistance inherent to titanium and its alloys has led to a wide and diversified range of successful applications which demand high levels of reliable performance in surgery, medicine, aerospace, automotive, chemical plant, power generation, oil and gas extraction, sports, and other major industries. In the majority of these engineering applications titanium has replaced heavier, less serviceable or less cost effective materials. Designing with titanium taking all factors into account has resulted in reliable, economic and more durable systems and components, which in many situations have substantially exceeded performance and service life expectations. Conventional machining of titanium requires forces only slighter higher than those needed to machine steel, but the alloys have metallurgical characteristics that make them somewhat more difficult to machine than steels of equivalent hardness on conventional machine tools. Many of titanium’s material characteristics make it expensive and hard to machine.
Literature Review
Several researchers have used this process for machining of wide variety of materials considering differentprocess parameters.Suhail et al. [6] Optimizes the cutting parameters such as cutting speed, feed rate and depth of cut based on surface roughness and assistance of work piece surface temperature in turning process. In machining operation the quality of surface finish is an important requirement for many turned work pieces. The work piece surface temperature can be sensed and used effectively as an indicator to control the cutting performance and improves the optimization process. So it is possible to increase machine utilization and decrease production cost in an automated manufacturing environment. Kirby [7] optimizes the turning process toward an ideal surface roughness target. This study seeks an actual target surface roughness value, which may allow for a higher feed rate depending upon that specified target. In using the variation of the nominal the-best signal to noise formula, variation about a specified (ideal) value is explored and sought to be minimized. Singh [8] optimizes tool life of Carbide Inserts for turned parts. The experiments were carried to obtain an optimal setting of turning process parameters- cutting speed, feed and depth of cut, which may result in optimizing tool life.
Experimental Methodology
The experiments are performed on conventional lathe machine CDL6241*1500 from Dalian Machine ToolGroup Corporation, China. A single point high speed steel (MIRANDA S-400) tool is used as the cutting tool. The round bar of Titanium grade 2, 40mm diameter and 50 mm length is used as the work piece. The input parameters viz. spindle speed, depth of cut and feed rate were varied to study their effect on material removal rate (MRR) and the tool failure. Their respective ranges are given in Table 1.
Conclusions
This study reveals that during machining of Titanium grade 2 on conventional lathe machine, MRR is affected by all the process parameters viz. spindle speed, depth of cut and feed rate. The MRR is increased by increasing any of the process parameters. The effect of variation in spindle speed and feed rate is more as compared to depth of cut. The tool failure takes place at higher values of depth of cut, feed rate and spindle speed. So in order to avoid the tool failure a compromise in the MRR must be made. This study is carried out for bracketing theoptimum range of three input parameters for carrying out further research.