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An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review
Materials Today: Proceedings xxx (xxxx) xxx
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Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review Rajesh Kumar Maurya a,b,⇑, M.S. Niranjan b a b
G.L. Bajaj Institute of Technology and Management, Greater Noida 201308, India Delhi Technological University, Delhi 201523, India
a r t i c l e
i n f o
Article history: Received 30 April 2019 Received in revised form 26 August 2019 Accepted 3 September 2019 Available online xxxx Keywords: EN-36C alloy steel GRA Taguchi method Surface roughness MRR CNC turning
a b s t r a c t EN-36C alloy steel has a wide application in the field of automobile and aerospace sector due to its splendid metallurgical properties. There are several studies are conducted to investigate the mechanical and surface properties of EN-36C alloy. The present study focuses on methodology presented by various researchers to investigate the mechanical properties of EN-36C alloy steel. In this work, an attempt is made to explore the various processes that can be used to improve the machinability with preserving their mechanical properties. Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
1. Introduction Turning is the secondary manufacturing process in which the excess material is removed from work material for getting a required shape, size and finish of the product. Turning operations are generally performed on manual center lathe machine as well as on CNC lathe machine. There is a great challenge to prepare a final product from hard metals to get required dimensional accuracy, close tolerances, surface finish, and MRR. Quality and productivity of machine tool depend on variety of machining parameters. Cutting condition is defined by the cutting parameters which have a major effect on the product quality. Tool variables include tool material along with tool signature and tool vibration. Work material parameters include hardness and softness of materials. These input process parameters have direct effect on surface roughness. But it is very difficult to control all these variables at a single time for quality products [1]. During turning of metals on CNC lathe, three forces are developed on the cutting tool i.e. cutting force (Fz) as well as thrust force (Fy) and feed force (Fx). Cutting force has a great influence on power consumptions among all. Surface finishes of machined parts have a great importance to control the process that results in the surface needed. It is very important
⇑ Corresponding author. E-mail address: [email protected] (R.K. Maurya).
factors that control friction during sliding, to improve look, feel of a product, and fit between parts. Apart from these it also affects conduction of heat, electrical currents, reflectivity of the surface adhesion of paints and coating. So in modern industry the accuracy and surface finish have become a primary needs. Various methods and technique are available to evaluate the surface roughness. Methods may be conventional or unconventional. Unconventional method has better speed and accuracy as compare to conventional one [2]. Even though for optimizing the turning responses some statistical tools such as Taguchi and grey relational analysis (GRA) are used. EN-36C alloy steel is the hard material turned on CNC lathe with the help of tungsten carbide tool. Responses are optimized in better and robust way with the help of GRA statistical tool as compared to the Taguchi method [3].
2. State-of-the-art Abhang et al. [4] experimentally analyzed the optimization of surface roughness and tool wear during the CNC turning of EN31steel with using tungsten carbide inserts. Experiment were carried out at five different controllable factors such as speed, feed, depth of cut, tool nose radius and different solid –liquid lubricants with suing of response surface methodology (RSM). Bharilya et al. [5] have optimized the machining parameters during CNC turning of mild steel, Aluminium alloys and Brass (soft material) by
https://doi.org/10.1016/j.matpr.2019.09.008 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
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reducing cutting forces through force dynamometer. Surface finishes were compared of the same. Palanisamy et al. [6] have studied the optimization parameters through the experiments during the CNC turning of Incoloy 800H. Here depth of cut, feed rate and speed were taken as machining parameters. The output responses as surface roughness and material removal rate were optimized via Taguchi - Based Grey Relational Analysis. Das et al. [7] have described and analyzed the surface roughness, tool wear, chip morphology during the turning of AISI 4340 steel in CNC lathe using multilayer coated carbide tool. It uses three factors and three levels with Taguchi L9 orthogonal array. Chip morphology was observed through scanning electron microscope (SEM). Ramana et al. [8] have experimentally investigated the material removal rate in turning of AISI 321 Austenitic Stainless Steel in CNC lathe with the use of CVD and PVD coated tool. Taguchi method is used to optimize the process parameters for maximize the material removal rate. Kamdar et al. [9] have investigated the cutting force, feed force and surface roughness during the CNC turning of EN-36 alloy steel under varying condition of temperatures from 200 °C to 600 °C by using flame heating at constant depth of cut 0.8 mm. Experiments has been carried out under three control factors namely surface temperatures, feeds rates and cutting speed. For optimizing the process parameters Taguchi and ANOVA have been adopted. Finding s of this paper is that the cutting force and feed force are deceased with increase in temperature. Here the temperature is most significant factor for cutting and feed force. Good surface finish achieved at hot surface with high cutting speed and low feed rate. Consumptions of power are low at hot machining but it increases with increase in speed and feed. In hot machining even low cutting speed are able to produce continuous chips. Kulshreshtha et al. [10] experimentally analyzed the effect of cutting parameters (cutting speed and depth of cut) on surface roughness while turning the EN-36 alloy steel on CNC lathe. The finding of this paper is that feed rate has most affecting parameter followed by depth of cut and cutting speed has least significant on surface roughness. Prabha et al. [11] envisaged the wear of the tool while turning EN- 36 alloy steel with coated and uncoated tool insert on CNC lathe machine at high speed. The flank wear pattern has been observed with coated and uncoated tools insert by tool maker’s
microscope. The Comparative study of both insert has been made and found that turning with coated tool insert gave the better results as compare with uncoated at higher speed. Uncoated insert got more wear at higher speed than coated insert. The microscopic image of flank wear of coated insert has been shown in Fig. 1 [11] and for uncoated shown in Fig. 2 [11]. Singh et al. [12] experimentally analyzed the axial force, main cutting force, radial force and material removal rate at different process parameters (cutting speed, feed rate and depth of cut) while turning of EN-36(655 M13) on CNC lathe in dry condition by using carbide cutting tool. Taguchi tool is adopted for optimizing the responses by appropriate setting of parameters. It had been seen that the cutting speed was more influential parameter for forces whereas depth of cut and feed rate were found less affecting parameters for the forces. Vishnu et al. [13] presented the experimental data to optimize the cutting parameters in turning of EN-36 alloy steel on CNC lathe in order to improve the material removal rate. Taguchi technique has been adopted with four control factors and three levels for each control factor. L9 (34) orthogonal array was used to perform the experiments. The optimal condition for material removal rate was observed at the speed of 100 m/min, feed rate (0.4 mm/rev) and Depth of cut 1 mm. Gosai et al. [14] have presented an experimental set up for finding the average temperature of CNMG4325 Grade TN2000 Coated carbide insert cutting tool while turning the EN-36 alloy steel on CNC lathe. The average temperature of tool was found with the help of analog k- type thermocouple sensor placing on cutting tool. CCD based RSM was used to optimize the cutting parameters. A complete experimental set up has been shown in Fig. 3 through which average tool temperature could be measured. Naidu et al. [15] have investigated the optimization of selected cutting parameters such as cutting speed, depth of cut, feed rate and type of lubricants during the turning of EN-36 alloy steel on CNC lathe with the help of carbide tool. Here lubricants used as vegetable oil and vegetable oil plus boric acid. Orthogonal array of L9 (34) has been used to perform the experiments and optimize the parameters through Taguchi approach. Material removal rate (MMR) was calculated for all set of experiments as an output response and optimization of process parameters has been carried out for the same response parameter.
Fig. 1. Flank Wear at 150 rpm 0.2 mm and 0.4 mm depth of cut for coated insert.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
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Fig. 2. Flank Wear at 150 rpm 0.2 mm and 0.4 mm depth of cut for uncoated insert.
Kumar et al. [16] presented the optimization of machining parameters namely cutting speed and feed rate during the turning of different alloy steels such as EN47, EN19, EN8, EN24 and SAE8620 on CNC lathe with the use of carbide tip tool. Surface roughness was measured for each sample with the help of surface roughness tester of stylus type SJ-301. It has been found that the surface roughness was greatly influenced by feed rate and followed by at lower speeds. Vishnu et al. [17] have investigated experimentally to optimize the cutting parameters during the turning of EN36 on CNC lathe by using carbide tool. Here the process parameters are Cutting Speed, Feed rate, Depth of cut and types of lubricants. Experiments are carried out using orthogonal array of L9 (34). Taguchi method is used to minimize the cutting temperature as an output response. The optimum values for cutting temperature were calculated by measured value of cutting temperature from
different experiments. Author found that the optimum values for response were speed 500 m/min, feed 0.4 mm/min and Depth of cut 5 mm. Veg oil + Boric Acid observed as robust lubricants. Korat et al. [18] experimentally analyzed to optimize the input cutting parameters on surface finish and MRR during the turning of EN24 on CNC lathe machine using Taguchi methods. Tungsten carbide inserts coated with TiN used as cutting tool. In this experiment speed, feed rate, depth of cut, nose radius and cutting environment (wet and dry) used as a cutting process parameters. Jadhav et al. [19] have experimentally investigate to optimize the input cutting parameters effect on surface roughness and material removal rate during the turning of EN36 alloy steel using coated carbide. L27 has been carried out for performing the experiments using Taguchi technique in dry environment. Garg et al. [20] have investigated the effect of process variables on MRR and surface
Fig. 3. Experimental setup for measuring tool temperature [14].
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
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Fig. 4. Experimental setup for calibrating the tool-work thermocouple [21].
finish while turning EN24/EN8/EN36 alloy steel on CNC lathe using Taguchi technique. Experiments were carried out using L18 orthogonal array on Minitab 16 statistical software. Abhang et al. [21] have presented an experiment set up for measuring temperature between tool and chip during turning of EN-31 alloy steel on CNC lathe machine using tungsten carbide insert. Tool-work thermocouple techniques were used here. Response surface methodology is used for analyzing the results. Cutting Speed, feed rate, nose radius and depth of cut were used as cutting process parameters. It has been found that cutting speed, feed rate and depth of cut were more influencing parameters for tool-chip interface followed by nose radius. Interface temperature between tool and chip increased on increasing of cutting speed, feed rate and depth of cut while decreased on increasing of nose radius. The experimental setup for calibrating the tool-work interface has been shown in Fig. 4 [21] below. Thermocouple junction was prepared with the help of work material EN-31, tungsten carbide as a tool material and two copper plates which clamps the work and tool material. A standard Alumel-chromel used as thermocouple. Dave et al. [22] have presented the experiments for finding the optimized input cutting parameters while turning the different grade of EN material on CNC lathe machine with the help of cutting tool coated with TiN. The aim of the work was to minimize the surface roughness and maximized the material removal rate using Taguchi method. It has been found that depth of cut play an important role in MMR and insert of the tool in lower surface roughness. Paventhan et al. [23] experimentally analyzed to increase the wear resistance of an EN 36 feed roller by hard facing process. Hard facing is the process of increasing the hardness of the parent metal by coating the hard electrode such as MAGNA 402 and 403with the help of shielded metal arc welding. It has been found that the life of feed roller get increased 5–6 month more. Gowd et al. [24] have investigated to optimize the input cutting parameters during the turning of EN-31 on CNC lathe. ANN was applied on chosen output responses for model prediction. Adequacy testing of models has been done by ANOVA analysis. Singh et al. [25] have experimentally presented to optimize the cutting parameters for responses during turning of EN 36 alloy steel on CNC lathe under dry cutting condition. The aim of this paper was to minimize surface roughness and maximize MRR. It had been found that feed rate play a significant role in surface roughness while depth of cut in MRR. Singh et al. [26] have experimentally investigate to optimize the cutting parameters during turning of EN-36 alloy steel on CNC lathe under dry and wet cutting conditions for surface roughness and material removal rate (MRR), cutting speed, feed rate, depth of cut, nose radius and cutting environment (wet and dry) are taken as input parameters. Taguchi
technique is used for optimizing the input process parameters. Routara et al. [27] have experimentally analyzed to optimize the cutting parameters during the CNC turning of EN-8 alloy steel for minimization of surface roughness. It has been found that surface roughness value was minimum at maximum value of depth of cut and speed while maximum at maximum value of feed rate. 3. Conclusions Based on thorough literature survey on Turning of EN-36C alloy steel, it has been observed that most of the researchers have done their work on optimization of material removal rate (MRR) and
Fig. 5. Percentage contribution of input process parameters.
Fig. 6. Percentage contribution of output responses.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
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surface roughness of the work parts. Few of them have found the wear rate of tool and tool- chip interface temperature. None of them have discussed about how to increase the machinability of EN-36C alloy steel by appropriate technique with preserving their properties. The percentage contribution of all input process parameters used in reviewed papers has been shown in pie chart of Fig. 5. It has been observed from reviewed papers that for the surface roughness most affecting parameters are feed rate, cutting speed and nose radius and least affecting parameter is depth of cut (DOC) and for material removal rate (MRR) most appropriate parameters are DOC and feed rate, cutting speed are least affecting parameters. The percentage contributions of output responses are shown in Fig. 6. It is clear from the pie chart that surface roughness has major contribution of 35% followed by material removal rate (MRR) 31% as an output responses used by researchers. Whereas tool temperature, wear rate and forces have the % age contribution of 14%, 10% and 10% respectively. It could be seen from the literature survey that in turning of EN-36C alloy steel, the main focus of researchers were on finding of surface roughness and MRR. 4. Future work EN-36C alloy steel has very wide application in different fields. Due to marvelous degree of toughness along with hard case and strong core it is suitable for ball bearing and roller of extra light section. Generally crankshafts, rollers of aero plane and motor are made up of this material. It is also used as connecting rod, highly stressed gudgeon pins, gears and certain types of collets etc. mostly it has been found that all researchers have optimized the input parameters for achieving the better responses but none have mentioned how to increase the machinability of the EN-36C alloy steel by using some technique or methods with preserving their properties. On the basis of this work could be done on quality parameters like power consumption, MRR, surface roughness, geometric tolerance like circularity, cylindricity, perpendicularity etc.
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It has been found that largely research papers have been carried out with the use of Taguchi technique only. Very few papers were based on the grey relational analysis (GRA). GRA approach is more suitable for optimization of multi-responses as compare to Taguchi method. References [1] A. Prakash, Imp. J. Interdiscip. Res. 5 (2016) 299–306. [2] C.J. Rao, D. Nageswara Rao, P. Srihari, Proc. Eng. 64 (2013) 1405–1415. [3] R.K. Maurya, M.S. Niranjan, Nagendra Kumar Maurya, Int. J. Eng. Technol. 7 (2018) 447–453. [4] L. Abhang, M. Hameedullah, Mater. Today: Proc. 2 (2015) 2640–2647. [5] R.K. Bharilya, R. Malgaya, L. Patidar, R.K. Gurjar, A.K. Jha, Mater. Today: Proc. 2 (2015) 2300–2305. [6] A. Palanisamy, T. Selvaraj, Mater. Today: Proc. 5 (2018) 7708–7715. [7] S.R. Das, A. Panda, D. Dhupal, Mater. Today: Proc. 5 (2018) 6560–6569. [8] M.V. Ramana, G. Kumar, Mater. Today: Proc. 5 (2018) 4965–4970. [9] N.M. Kamdar, V.K. Patel, Int. J. Eng. Res. Appl. 3 (2012) 1833–1838. [10] M. Kulshreshtha, IJAIST 16 (2013) 9–15. [11] K.A. Prabha, B.S. Prasad, N. Srilatha, Mater. Today: Proc. 5 (2018) 4368–4375. [12] R. Singh, D. Gautam, Int. J. Adv. Sci. Res. Manage. 6 (2016) 4351–4354. [13] A.V. Vishnu, G.G. Naidu, K.B.G. Tilak, J. Ramakrishna, Int. J. Adv. Eng. Res. Dev. 8 (2015) 54–62. [14] M. Gosai, S.N. Bhavsar, Procedia Technol. 23 (2016) 311–318. [15] G.G. Naidu, A.V. Vishnu, S.N. Kumar, T.P. Sagar, M.G. Srinivas, J. Int, Adv. Res. Innov. Ideas Educ. 2 (2017) 28–32. [16] N.S. Kumar, A. Shetty, A. Shetty, K. Ananth, H. Shetty, Procedia Eng. 38 (2012) 691–697. [17] A.V. Vishnu, E. Sanjana, G.G. Naidu, J. Int, Adv. Res. Innov. Ideas Educ. 2 (2017) 1–6. [18] M. Korat, N. Agarwal, Int. J. Eng. Res. Appl. 5 (2012) 160–164. [19] S. Jadhav, V. Sabnis, Int. J. Res. Eng. Technol. 11 (2017) 562–568. [20] M. Garg, S. Sangwan, M. Kainth, IJETR 2 (2016) 82–85. [21] L.B. Abhang, M. Hameedullah, Int. J. Eng. Sci. Technol. 4 (2010) 382–393. [22] H.K. Dave, L.S. Patel, H.K. Raval, Int. J. Ind. Eng. Comput. 3 (2012) 925–930. [23] R. Paventhan, C. Rajesh, Int. J. Adv. Res. Technol. 3 (2015) 120–123. [24] G.H. Gowd, M.V. Goud, K.D. Theja, M.G. Reddy, Procedia Eng. 97 (2014) 125– 133. [25] A. Singh, H. Singh, Int. J. Curr. Eng. 7 (2017) 915–920. [26] K.P. Singh, G.D. Gautam, R. Yadav, L. Bisht, G. Norkey, Int. J. Sci. Eng. Res. 5 (2014) 976–982. [27] B.C. Routara, A.K. Sahoo, A.K. Parida, P.C. Padhi, Procedia Eng. 38 (2012) 1893– 1904.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review Rajesh Kumar Maurya a,b,⇑, M.S. Niranjan b a b
G.L. Bajaj Institute of Technology and Management, Greater Noida 201308, India Delhi Technological University, Delhi 201523, India
a r t i c l e
i n f o
Article history: Received 30 April 2019 Received in revised form 26 August 2019 Accepted 3 September 2019 Available online xxxx Keywords: EN-36C alloy steel GRA Taguchi method Surface roughness MRR CNC turning
a b s t r a c t EN-36C alloy steel has a wide application in the field of automobile and aerospace sector due to its splendid metallurgical properties. There are several studies are conducted to investigate the mechanical and surface properties of EN-36C alloy. The present study focuses on methodology presented by various researchers to investigate the mechanical properties of EN-36C alloy steel. In this work, an attempt is made to explore the various processes that can be used to improve the machinability with preserving their mechanical properties. Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
1. Introduction Turning is the secondary manufacturing process in which the excess material is removed from work material for getting a required shape, size and finish of the product. Turning operations are generally performed on manual center lathe machine as well as on CNC lathe machine. There is a great challenge to prepare a final product from hard metals to get required dimensional accuracy, close tolerances, surface finish, and MRR. Quality and productivity of machine tool depend on variety of machining parameters. Cutting condition is defined by the cutting parameters which have a major effect on the product quality. Tool variables include tool material along with tool signature and tool vibration. Work material parameters include hardness and softness of materials. These input process parameters have direct effect on surface roughness. But it is very difficult to control all these variables at a single time for quality products [1]. During turning of metals on CNC lathe, three forces are developed on the cutting tool i.e. cutting force (Fz) as well as thrust force (Fy) and feed force (Fx). Cutting force has a great influence on power consumptions among all. Surface finishes of machined parts have a great importance to control the process that results in the surface needed. It is very important
⇑ Corresponding author. E-mail address: [email protected] (R.K. Maurya).
factors that control friction during sliding, to improve look, feel of a product, and fit between parts. Apart from these it also affects conduction of heat, electrical currents, reflectivity of the surface adhesion of paints and coating. So in modern industry the accuracy and surface finish have become a primary needs. Various methods and technique are available to evaluate the surface roughness. Methods may be conventional or unconventional. Unconventional method has better speed and accuracy as compare to conventional one [2]. Even though for optimizing the turning responses some statistical tools such as Taguchi and grey relational analysis (GRA) are used. EN-36C alloy steel is the hard material turned on CNC lathe with the help of tungsten carbide tool. Responses are optimized in better and robust way with the help of GRA statistical tool as compared to the Taguchi method [3].
2. State-of-the-art Abhang et al. [4] experimentally analyzed the optimization of surface roughness and tool wear during the CNC turning of EN31steel with using tungsten carbide inserts. Experiment were carried out at five different controllable factors such as speed, feed, depth of cut, tool nose radius and different solid –liquid lubricants with suing of response surface methodology (RSM). Bharilya et al. [5] have optimized the machining parameters during CNC turning of mild steel, Aluminium alloys and Brass (soft material) by
https://doi.org/10.1016/j.matpr.2019.09.008 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
2
R.K. Maurya, M.S. Niranjan / Materials Today: Proceedings xxx (xxxx) xxx
reducing cutting forces through force dynamometer. Surface finishes were compared of the same. Palanisamy et al. [6] have studied the optimization parameters through the experiments during the CNC turning of Incoloy 800H. Here depth of cut, feed rate and speed were taken as machining parameters. The output responses as surface roughness and material removal rate were optimized via Taguchi - Based Grey Relational Analysis. Das et al. [7] have described and analyzed the surface roughness, tool wear, chip morphology during the turning of AISI 4340 steel in CNC lathe using multilayer coated carbide tool. It uses three factors and three levels with Taguchi L9 orthogonal array. Chip morphology was observed through scanning electron microscope (SEM). Ramana et al. [8] have experimentally investigated the material removal rate in turning of AISI 321 Austenitic Stainless Steel in CNC lathe with the use of CVD and PVD coated tool. Taguchi method is used to optimize the process parameters for maximize the material removal rate. Kamdar et al. [9] have investigated the cutting force, feed force and surface roughness during the CNC turning of EN-36 alloy steel under varying condition of temperatures from 200 °C to 600 °C by using flame heating at constant depth of cut 0.8 mm. Experiments has been carried out under three control factors namely surface temperatures, feeds rates and cutting speed. For optimizing the process parameters Taguchi and ANOVA have been adopted. Finding s of this paper is that the cutting force and feed force are deceased with increase in temperature. Here the temperature is most significant factor for cutting and feed force. Good surface finish achieved at hot surface with high cutting speed and low feed rate. Consumptions of power are low at hot machining but it increases with increase in speed and feed. In hot machining even low cutting speed are able to produce continuous chips. Kulshreshtha et al. [10] experimentally analyzed the effect of cutting parameters (cutting speed and depth of cut) on surface roughness while turning the EN-36 alloy steel on CNC lathe. The finding of this paper is that feed rate has most affecting parameter followed by depth of cut and cutting speed has least significant on surface roughness. Prabha et al. [11] envisaged the wear of the tool while turning EN- 36 alloy steel with coated and uncoated tool insert on CNC lathe machine at high speed. The flank wear pattern has been observed with coated and uncoated tools insert by tool maker’s
microscope. The Comparative study of both insert has been made and found that turning with coated tool insert gave the better results as compare with uncoated at higher speed. Uncoated insert got more wear at higher speed than coated insert. The microscopic image of flank wear of coated insert has been shown in Fig. 1 [11] and for uncoated shown in Fig. 2 [11]. Singh et al. [12] experimentally analyzed the axial force, main cutting force, radial force and material removal rate at different process parameters (cutting speed, feed rate and depth of cut) while turning of EN-36(655 M13) on CNC lathe in dry condition by using carbide cutting tool. Taguchi tool is adopted for optimizing the responses by appropriate setting of parameters. It had been seen that the cutting speed was more influential parameter for forces whereas depth of cut and feed rate were found less affecting parameters for the forces. Vishnu et al. [13] presented the experimental data to optimize the cutting parameters in turning of EN-36 alloy steel on CNC lathe in order to improve the material removal rate. Taguchi technique has been adopted with four control factors and three levels for each control factor. L9 (34) orthogonal array was used to perform the experiments. The optimal condition for material removal rate was observed at the speed of 100 m/min, feed rate (0.4 mm/rev) and Depth of cut 1 mm. Gosai et al. [14] have presented an experimental set up for finding the average temperature of CNMG4325 Grade TN2000 Coated carbide insert cutting tool while turning the EN-36 alloy steel on CNC lathe. The average temperature of tool was found with the help of analog k- type thermocouple sensor placing on cutting tool. CCD based RSM was used to optimize the cutting parameters. A complete experimental set up has been shown in Fig. 3 through which average tool temperature could be measured. Naidu et al. [15] have investigated the optimization of selected cutting parameters such as cutting speed, depth of cut, feed rate and type of lubricants during the turning of EN-36 alloy steel on CNC lathe with the help of carbide tool. Here lubricants used as vegetable oil and vegetable oil plus boric acid. Orthogonal array of L9 (34) has been used to perform the experiments and optimize the parameters through Taguchi approach. Material removal rate (MMR) was calculated for all set of experiments as an output response and optimization of process parameters has been carried out for the same response parameter.
Fig. 1. Flank Wear at 150 rpm 0.2 mm and 0.4 mm depth of cut for coated insert.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
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Fig. 2. Flank Wear at 150 rpm 0.2 mm and 0.4 mm depth of cut for uncoated insert.
Kumar et al. [16] presented the optimization of machining parameters namely cutting speed and feed rate during the turning of different alloy steels such as EN47, EN19, EN8, EN24 and SAE8620 on CNC lathe with the use of carbide tip tool. Surface roughness was measured for each sample with the help of surface roughness tester of stylus type SJ-301. It has been found that the surface roughness was greatly influenced by feed rate and followed by at lower speeds. Vishnu et al. [17] have investigated experimentally to optimize the cutting parameters during the turning of EN36 on CNC lathe by using carbide tool. Here the process parameters are Cutting Speed, Feed rate, Depth of cut and types of lubricants. Experiments are carried out using orthogonal array of L9 (34). Taguchi method is used to minimize the cutting temperature as an output response. The optimum values for cutting temperature were calculated by measured value of cutting temperature from
different experiments. Author found that the optimum values for response were speed 500 m/min, feed 0.4 mm/min and Depth of cut 5 mm. Veg oil + Boric Acid observed as robust lubricants. Korat et al. [18] experimentally analyzed to optimize the input cutting parameters on surface finish and MRR during the turning of EN24 on CNC lathe machine using Taguchi methods. Tungsten carbide inserts coated with TiN used as cutting tool. In this experiment speed, feed rate, depth of cut, nose radius and cutting environment (wet and dry) used as a cutting process parameters. Jadhav et al. [19] have experimentally investigate to optimize the input cutting parameters effect on surface roughness and material removal rate during the turning of EN36 alloy steel using coated carbide. L27 has been carried out for performing the experiments using Taguchi technique in dry environment. Garg et al. [20] have investigated the effect of process variables on MRR and surface
Fig. 3. Experimental setup for measuring tool temperature [14].
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
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Fig. 4. Experimental setup for calibrating the tool-work thermocouple [21].
finish while turning EN24/EN8/EN36 alloy steel on CNC lathe using Taguchi technique. Experiments were carried out using L18 orthogonal array on Minitab 16 statistical software. Abhang et al. [21] have presented an experiment set up for measuring temperature between tool and chip during turning of EN-31 alloy steel on CNC lathe machine using tungsten carbide insert. Tool-work thermocouple techniques were used here. Response surface methodology is used for analyzing the results. Cutting Speed, feed rate, nose radius and depth of cut were used as cutting process parameters. It has been found that cutting speed, feed rate and depth of cut were more influencing parameters for tool-chip interface followed by nose radius. Interface temperature between tool and chip increased on increasing of cutting speed, feed rate and depth of cut while decreased on increasing of nose radius. The experimental setup for calibrating the tool-work interface has been shown in Fig. 4 [21] below. Thermocouple junction was prepared with the help of work material EN-31, tungsten carbide as a tool material and two copper plates which clamps the work and tool material. A standard Alumel-chromel used as thermocouple. Dave et al. [22] have presented the experiments for finding the optimized input cutting parameters while turning the different grade of EN material on CNC lathe machine with the help of cutting tool coated with TiN. The aim of the work was to minimize the surface roughness and maximized the material removal rate using Taguchi method. It has been found that depth of cut play an important role in MMR and insert of the tool in lower surface roughness. Paventhan et al. [23] experimentally analyzed to increase the wear resistance of an EN 36 feed roller by hard facing process. Hard facing is the process of increasing the hardness of the parent metal by coating the hard electrode such as MAGNA 402 and 403with the help of shielded metal arc welding. It has been found that the life of feed roller get increased 5–6 month more. Gowd et al. [24] have investigated to optimize the input cutting parameters during the turning of EN-31 on CNC lathe. ANN was applied on chosen output responses for model prediction. Adequacy testing of models has been done by ANOVA analysis. Singh et al. [25] have experimentally presented to optimize the cutting parameters for responses during turning of EN 36 alloy steel on CNC lathe under dry cutting condition. The aim of this paper was to minimize surface roughness and maximize MRR. It had been found that feed rate play a significant role in surface roughness while depth of cut in MRR. Singh et al. [26] have experimentally investigate to optimize the cutting parameters during turning of EN-36 alloy steel on CNC lathe under dry and wet cutting conditions for surface roughness and material removal rate (MRR), cutting speed, feed rate, depth of cut, nose radius and cutting environment (wet and dry) are taken as input parameters. Taguchi
technique is used for optimizing the input process parameters. Routara et al. [27] have experimentally analyzed to optimize the cutting parameters during the CNC turning of EN-8 alloy steel for minimization of surface roughness. It has been found that surface roughness value was minimum at maximum value of depth of cut and speed while maximum at maximum value of feed rate. 3. Conclusions Based on thorough literature survey on Turning of EN-36C alloy steel, it has been observed that most of the researchers have done their work on optimization of material removal rate (MRR) and
Fig. 5. Percentage contribution of input process parameters.
Fig. 6. Percentage contribution of output responses.
Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008
R.K. Maurya, M.S. Niranjan / Materials Today: Proceedings xxx (xxxx) xxx
surface roughness of the work parts. Few of them have found the wear rate of tool and tool- chip interface temperature. None of them have discussed about how to increase the machinability of EN-36C alloy steel by appropriate technique with preserving their properties. The percentage contribution of all input process parameters used in reviewed papers has been shown in pie chart of Fig. 5. It has been observed from reviewed papers that for the surface roughness most affecting parameters are feed rate, cutting speed and nose radius and least affecting parameter is depth of cut (DOC) and for material removal rate (MRR) most appropriate parameters are DOC and feed rate, cutting speed are least affecting parameters. The percentage contributions of output responses are shown in Fig. 6. It is clear from the pie chart that surface roughness has major contribution of 35% followed by material removal rate (MRR) 31% as an output responses used by researchers. Whereas tool temperature, wear rate and forces have the % age contribution of 14%, 10% and 10% respectively. It could be seen from the literature survey that in turning of EN-36C alloy steel, the main focus of researchers were on finding of surface roughness and MRR. 4. Future work EN-36C alloy steel has very wide application in different fields. Due to marvelous degree of toughness along with hard case and strong core it is suitable for ball bearing and roller of extra light section. Generally crankshafts, rollers of aero plane and motor are made up of this material. It is also used as connecting rod, highly stressed gudgeon pins, gears and certain types of collets etc. mostly it has been found that all researchers have optimized the input parameters for achieving the better responses but none have mentioned how to increase the machinability of the EN-36C alloy steel by using some technique or methods with preserving their properties. On the basis of this work could be done on quality parameters like power consumption, MRR, surface roughness, geometric tolerance like circularity, cylindricity, perpendicularity etc.
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Please cite this article as: R. K. Maurya and M. S. Niranjan, An experimental analysis of process parameters for EN-36C alloy steel using CNC lathe – A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.008