Investigation of various cutting

parameters on heat generation

During machining process
(Review based)

A PROJECT REPORT
Submitted in partial fulfilment of the

requirement for the award of the

degree of

BACHELOR OF TECHNOLOGY (B.Tech)

in
(Mechanical Engineering)
by

(Vivek Ku. Pandey, Vaibhav Rathore)

(179402167,179402157)

(Mechanical Engineering)
MANIPAL UNIVERSITY
JAIPUR JAIPUR-303007
 RAJASTHAN, INDIA
Jan/2021
 DEPARTMENT OF MECHANICAL ENGINEERING

MANIPAL UNIVERSITY JAIPUR, JAIPUR – 303 007 (RAJASTHAN), INDIA

Date

CERTIFICATE

This is to certify that the project titled Investigation and analysis of various
cutting parameter on heat generation metal cutting operation and its
measurement review based is a record of the bonafide work done by VIVEK
PANDEY, VAIBHAV SINGH RATHORE (179402167,179402157) submitted in
partial fulfilment of the requirements for the award of the Degree of Bachelor of
Technology (B.Tech) in (Mechanical Engineering) of Manipal University Jaipur,
during the academic year 2020-21

Dr. Ashok Kumar Sharma

Project Guide, Dept of mechanical engineering

Manipal University Jaipur

Dr. Rahul Goyal

HOD, Dept of mechanical engineering

Manipal University Jaipur

 (On company letterhead)

Date

CERTIFICATE

This is to certify that the project entitled Investigation and analysis of various

cutting parameter on heat generation metal cutting operation and its

measurement was carried out by VIVEK PANDEY, VAIBHAV SINGH

(179402167,179402157) at MANIPAL UNIVERSITY JAIPUR, JAIPUR under

my guidance during January, 2021 to May.

Dr. Ashok Kumar Sharma

Professor,

MANIPAL UNIVERSITY JAIPUR, JAIPUR

 ACKNOWLEDGMENTS

We would like to thank our project guide Dr Ashok Kumar Sharma for their guidance and support in
completing our seminar project. We would also like to extend our gratitude to the Head of the
Department of Mechanical Engineering Dr Rahul Goyal for providing all the facilities required for
successful completion of our seminar project.

VIVEK KUMAR PANDEY,179402167

VAIBHAV SINGH RATHORE,179402157

 ABSTRACT

Metal cutting processes usually cause heat generation at the cutting zone (around the
workpiece-tool intersection). The heat generated during these processes may cause
different effects on both the workpiece and tool, this in turn may affect the finished
product and the general performance of the machined piece. In this study, a review was
done on various types of machining conditions available, effects and analysis of heat
generated on the workpiece and tool, and the approaches adopted to reduce this heat at
cutting zones.

It was discovered that heat generation causes two major types of wear on the tool,
crater and flank wear, resulting in the reduction of cutting tool life as well as
dimensional inaccuracy, surface damage and severe corrosion cases on the workpiece.
Various heat reduction methods and coolant application types were as well studied and
their merits and demerits were discussed.
In this paper a review has been done on the various parameters of heat generation and
its considerable effects on the life of the cutting tool and the quality of the machined
part.

Subjects taught at the university namely Production Technology part1,2, Heat Transfer
and Metrology helped me a lot for understanding various terms and for calculations of
various data. Our main purpose is to find out how much heat generated by changing
various parameters and what its effect is on tools and workpiece.
 LIST OF TABLES
Table Page
No Table Title No

1 Number of review papers and their sequences 16

2 Experiments and different cutting parameters 32

3 Cutting parameters 41

4 Cutting fluid analysis 44

5 Tools comparisons 48

6 Cutting Temperature during machining in various conditions 49

LIST OF FIGURES
Figure Page
No Figure Title No

1 Heat generation and distribution in various planes 9

2 NOVIANO cutting tool 12

3 Carbide tool 13

4 HSS tool 14

5 Tool Terminology 16

6 K type thermocouple 16

7 CNC Milling machine 40

8 Therma CAM SC3000 40

9 CNC milling machine 41

10 thermocouple setup and circuit diagram of filter circuit 43
11 MICROGRAPHIC STRUCTURE OF VARIOUS SPECIMEN 48
12 Heat distribution diagram 51
 Contents
Page No
Acknowledgement i
Abstract ii
List Of Figures iii
List Of Tables vi
Chapter 1 INTRODUCTION 9
1.1 Motivation 9
1.2 Objectives of the Project 9
1.3 Organization of Report 10
Chapter 2 BACKGROUND MATERIAL 11
2.1 Conceptual Overview
2.2 Technologies Involved
.

.
Chapter 3 LITERATURE REVIEW 30
Chapter 4 METHODOLOGY 38
Chapter 5 IMPLEMENTATION 43
.
.
Last
RESULT AND ANALYSIS 44
Chapter
CONCLUSION
REFERENCES
 Chapter 1: Introduction
Metal removed in the form of chips. In manufacturing various processes are involved
such as turning, grinding, cutting, milling, drilling etc. All of these processes required
cutting tools but some if the conventional process such as forging, rolling, bending
doesn't require cutting tools. As we know that while machining lots of heat is
generated at the cutting force due to friction present at the surface of the workpiece
and cutting tools. The dissipated energy converts into heat and increases the
temperature of the cutting tools and workpiece surface. Almost 99% heat transferred
to chip cutting zones (shear zone) and cutting tools only 1% energy used for cutting
the metals.

There are three source of heat generation are-

● Shear-plane (AB), where the actual plastic deformation occurs

● Tool-chip interface (BC), due to the friction between tool and chip
● Tool-workpiece interface (BD), which occurs at flank surface

Fig. 1a.- heat distribution at different zones.

Much of the heat generated due to increase in machine removal rate with increase
in machine removal rate decreases the time by increasing the speed of cutting and
this will increase heat in cutting surfaces, this means that cutting tools should bear
more temperature so that cutting tools cannot lose their strength and shape, and
can resist high temperatures. For this we use cutting fluid so that the cooling effect
can be done so that proper cooling takes place and heat release from the tools
smoothly. Distinct types of cutting fluids are available in the market with different
chemical compositions and cutting parameters. Analysis of heat and measurement is
the main intention and to find a suitable route to reduce and overcome from this we
had chosen this paper.

1.1 MOTIVATION:
Measurement of heat during the machining process is an important task. Excess heat
causes wear and tear at the tool tip and damages the workpiece, surface finish and
dimensional accuracy is also disturbed, much of the power consumed during
machining process and this power converted in heat loss so economics of the
materials also affected. Our main motivation is to analyze and measure the heat
generation by changing machining parameters and find a way to reduce heat that is
generated during the process. To analyze heat and reduce this heat we had chosen this
research work.

1.2 OBJECTIVE:
Our main objective is to measure excess heat generated during the machining process
and with the help of data we find a way to reduce this heat generation so that
machining cost, dimensional accuracy can be achieved. To increase overall efficiency
of machining by removing heat is our final motto.

1.3 ORGANIZATION OF WORK:

This Review paper has been segregated into various components in the following
manner:

1. Downloaded and collected lots of research papers from various websites.

Started reading those downloaded and collected research papers.
2. Made a table that contains the author's name, their work outcomes like tools
used, techniques followed by him, parameters chosen by him and result and
conclusion obtained by him.
3. Extracted data and calculations from the existing research papers.
4. Started writing existing literature in our own language also methodology,
results, conclusions etc.

Chapter 2: Background Material

2.1 CONCEPTUAL OVERVIEW:
These review papers incorporated different types of tools, machines, and the
mechanisms that followed, a general idea about each of them was required to move
ahead with the work.

TOOL USED-

NOVIANO

The NOVIANO series is designed for highly efficient machining of alloy steel,
duplex and exotic materials such as Inconel and Titanium above 35 HRC.

Noviano aims to meet highly efficient machining strategies 

Benefits
● Suitable for dynamic milling
● One tool for many materials
● Cylindrical grinding of chamfer on cutting edge for improved surface quality
● Unequal spacing of end teeth reduces noise and vibration
● AICrN coating ensures good resistance to heat generation
Features
● Range includes mills with 4 cutting edges
● End mills with diameter range from ø3 – ø20 mm
● Roughing as well as finishing cutters
● A selection of various corner radii
● Suitable for regrinding
Applications
● Shoulder face milling
● Slot milling
● Profile milling

 fig.1b. NOVIANO cutting tool.

CARBIDE TOOL
In a wide sense, cemented carbide refers to composite alloys binding the hard grains
of carbides, nitrides, or carbonitrides of IVa, Va or VIa metals in the periodic table
with iron-based metal. In particular, WC-Co-based alloys are widely used due to their
excellent characteristics, and,general, cemented carbide is understood as WC-Co-
based alloy. 
 1. High hardness

fig.1c.

Hardness increases dramatically as tungsten binds with carbon, resulting in high

abrasion resistance.

2. High strength

fig.1d.

It is high in transverse rupture strength (bending strength), and delivers high

reliability against forces in bending direction.

3. High rigidity

fig.1e.

It has a high Young’s modulus (difficulty to bend), and excels in rigidity.

High-speed Steel – HSS

High-speed steels, abbreviated as HSS, are a specialized class of tool steels that were
named primarily for their ability to machine and cut materials at high speeds (high
hot hardness). It is often used in power-saw blades and drill bits. High-speed steel is
superior to the older high carbon steel tools in that it can withstand higher
temperatures without losing its temper (hardness). High-speed steels are complex
iron-base alloys of carbon, chromium, vanadium, molybdenum, or tungsten, or
combinations thereof. 

fig.1f.

High speed steel (HSS) is a tool steel with high hardness, high wear resistance and
high heat resistance. High-speed steel is often used in power-saw blades and drill
bits.

TYPES OF CUTTING FLUIDS USED:-

1. Water:
Water has high specific heat but is poor in lubrication. Also, it encourages rusting. It
is used as cooling agent during tool grinding.

2. Soluble Oils (Emulsions):

Soluble oils or emulsifiable oils are the largest type of cutting fluids used in
machining operations.

3. Mineral Oils:
Mineral oils are used for heavier cutting operations because of their good lubricating
properties. They are commonly found in production machines where high metal
removal rates are employed. They are most suitable for steels but should not be used
on copper or its alloys since it has a corrosive effect.

TOOLS TERMINOLOGY USED: -

Fig.2a. single cutting tools terminology, Reference by PN RAO

Fig.2b. drilling tool terminology[ref- https://www.sandvik.coromant.com/en-
gb/products/pages/drilling-tools.aspx]

THERMOCOUPLE:- A thermocouple is an electrical device consisting of two

dissimilar electrical conductors forming an electrical junction. A thermocouple
produces a temperature-dependent voltage as a result of Seebeck effect, and this
voltage can be interpreted to measure temperature.
 fig.2.c
- K-type thermocouple.

REVIEW PAPERS SEQUENCE SERIES: -

RESEARCH TOPIC AUTHOR TOOL USED RESULT

1.Analysing the effect of Patrick Adebisi Olusegun HSS and Carbide Straight oils provide the
cutting fluids on the Adegbuyi, Ganiyu Lawal, best lubrication
mechanical properties of Oluwatoyin Oluseye,
mild Ganiyu Odunaiya but poor cooling
capacities. Water, on the
steel in a turning other hand,
operation
is an effective cooling
agent, removing heat 2.5
times

more rapidly than oil.

Alone, water is a very
poor

lubricant and causes

rusting. Soluble oils or

chemicals that improve

lubrication prevent
corrosion

and provide other

essential qualities must be
added

in order to transform
water into a good
 metalworking

fluid

2.The Effects of Heat T.S. Ogedengbe, A. P. (a) Tungsten–Carbide (b) 1. The heat generated
Generation on Cutting Okediji, A. A. Yussouf, High Carbon could reduce the
Tool and Machined O. A. Aderoba, O. A. magnitude of the cutting
Abiola, I. O. Alabi and O. Steel forces leading to
Workpiece I. Alonge reduction

in power consumption
and then improve the
machinability of the
workpiece.

2. The heat generated

during machine
operations also affect the
material surface
roughness

significantly as there is a
direct relationship
between the two. High
values of surface

roughness could result in

an eventual failure of
parts fabricated

3. Tool life reduces with

an increase in heat
generation during
machine operations.
Coolants

play a pivotal role in

reducing the rate of heat
generation in machining.
However, it

might still pose a

challenge if not well
applied.

3.Heat generation and N.A. Abukhshim, P.T. Single point cutting tool fibre-optic pyrometers
temperature prediction in Mativenga, M.A. Sheikh and infrared
metal cutting: A review thermography techniques
and implications for high these techniques could
speed machining measure temperature, as
well as, the cooling rate
easily, accurately and
with fast time response

4.Optimization of Cutting Adeel H. Suhail, N. medium carbon steel AISI This study discussed an
Parameters Based on Ismail, S.V. Wong and 1020 application of the Taguchi
Surface Roughness and N.A. Abdul Jalil method for optimizing the
Assistance of Workpiece cutting parameters in
Surface Temperature in turning operations using
Turning Process combined of two
performance measures,
workpiece surface
Temperature (T) and
surface roughness (Ra)

5. The Influence of Sandip Patil, Shital Turning tool An increase in the cutting
Cutting Heat on the Jadhav, Swapnil Kekade, speed from 40 m/min to
Surface Ashish Supare, 140 m/min and an
increase in the feed rate
Integrity during Amit Powa , Dr. RKP from 0.2 mm/rev to 0.5
Machining of Titanium Singh mm/rev lead to higher
Alloy Ti6Al4V cutting temperature at the
cutting zone

because of enhanced
contact between tool and
workpiece and hence
increased friction.

2. At lower cutting
parameters, work
hardening phenomenon
however; at high cutting
parameters thermal
softening phenomenon
was found to be more
dominant. This was
derived from increased
surface roughness and
reduction in
microhardness values
beneath

the machined surface

along with coarse
microstructure obtained at
higher cutting parameters.

6. Influence of Cutting Junzhan Hou, Ning Zhao, Face milling cutter The temperature rise
Speed on Flank and Shaoli Zhu increases slightly when
Temperature the cutting speed is less
than 1507 m/min. When
during Face Milling of the cutting speed is up to
Magnesium Alloy more than 1507 m/min,
the temperature increases
significantly.

7. Analyses of Effects of Marcelo Ribeiro dos High speed steel tool Results are discussed in
Cutting Parameters on Santos, Sandro Metrevelle
Cutting Edge Marcondes de Lima e section.
Silva,
Temperature Using
Inverse Heat Conduction Álisson Rocha Machado,
Technique Márcio Bacci da Silva,
Gilmar Guimarães, and
Solidônio Rodrigues de
Carvalho

8. Chip- tool interface L. B. Abhang, and High speed steel tool The appropriate
temperature prediction M.Hameedullah aggregation among the
model for turning process cutting speed, feed rate,
depth of cut and tool nose
radius can generate
minimum cutting
temperature during steel
turning

9. Investigation of Cutting A. G. F. Alabi, T. K. High speed steel tool The temperature profile
Temperatures Distribution Ajiboye and H.D. obtained indicated that the
in Machine Heat Treated Olusegun tool has a higher
Medium Carbon Steel on machining temperature
a Lathe when machining steel
materials.

10. Temperature Sushil D. Ghodam Mild steel He pointed out that

measurement of a cutting generation of high
tool in turning process by temperature at the tool
using tool work rake face takes place due
thermocouple to the enormous frictional
forces caused at the tool-
chip interface. This
generation of heat can be
resisted by using a coated
tool. Reduction in the
temperature of the tool
improves the tool strength
and also improves the
surface roughness of the
work piece. From his
experimental data, it is
found that as compared to
uncoated tool the coating
of the tool increases the
life of a tool for the same
cutting velocity or for the
same tool life, coated tool
can be used at higher
cutting speed as compared
to uncoated tool.

11. Thermocouple and Abdil Kus, Yahya Isik, PVD TiAlN-TiN-coated They concluded that the
Infrared Sensor-Based M. Cemal Cakir, Salih WNVG080404-IC907 most important in
Measurement of Coşkun and Kadir reference to tool chip
Temperature Distribution Özdemir carbide interface is cutting speed.
in Metal Cutting According to their
research, most of the
important changes seen in
the chip formation and
curvature were due to the
increase in cutting speed
whereas the feed rate is
not of much importance.
They used the Techniques
like IR pyrometer and a
K-type thermocouple to
measure the temperature
of the tool and contact
behavior between tool-
chips in the turning
process of heat-treated
AISI 4140 alloy steel 50
HRC. By using multi-
sensor applications they
have studied the behavior
of cutting parameters
during heat distribution.
In order to verify the test
FEM results will be
playing a crucial role in
future studies, these
results are obtained based
on estimated heat over the
tool chip interface.

12. A review on selection Vamsi Krishna Mamidi High-speed steel, tungsten They concluded that the
of cutting fluids and M. Anthony Xavior carbide, cubic boron three major factors
nitride, polycrystalline affecting the cutting fluid
diamonds, ceramic and are the machining
diamond cutting tools process, workpiece
material and the cutting
tool material and they also
stated that proper
selection of cutting fluids
provides longer tool life,
higher surface finish
along with uninterrupted
cutting speeds, high
depth, and high feed rates.
They introduced a Dry
machining process in
which low cutting fluid is
applied during the
machining operation thus
lowering the cutting fluid
cost. The disposal cost
can also be minimized by
 using a method of
regeneration of fluids
which decreases the
environmental impact to a
greater extent.

13. Temperature A.A. Sri Rama Krishna, K-20 carbide cutting tool They stated that the
Prediction in Orthogonal Dr.P.Ravinder Reddy maximum temperature
Machining of A1/SiCp that can be found at the
Composites chip tool interface at a
cutting speed of 50m/min
is 315°C. Along with
radial and tangential
directions, the tool contact
temperature gradually
decreases from the chip
tool mating point to the
tool flank. They used
finite element results in
order to come to
conclusions.

14. Temperature rise Mr. Lathiya NE 9445 steel and AISI They stated that the
distribution due to the Dharmeshkumar and Mr. 1045 steel with a carbide quality of machined part
combined effects of shear Viswakarma Ajay tool and tool life is mainly
plane heat source and the influenced by the
tool chip interface temperature produced at
frictional heat source the different zones during
machining operations.
Also the study of
temperature at various
zones during the
machining process helps
to reduce production cost
and increase tool life.
They used MATLAB for
the determination of the
distribution of
temperature of five
different types of metal
cutting operations.

15. Predictive modeling of Özel, T., & Karpat, Y. hardened AISI H-13 steel They used neural network
surface roughness and modeling to predict
tool wear in hard turning surface roughness and tool
using regression and flank wear over the
neural networks machining time for a
variety of cutting
conditions in the finish
hard turning of their tool.
Regression models were
also developed to capture
 processing parameters.

16. Surface roughness Chavoshi, S. Z., & AISI 4140 using CBN They found the effect of
modeling in the hard Tajdari, M. cutting tool spindle speed and material
turning operation of AISI hardness variations on the
4140 using CBN cutting surface roughness of
tool. hardened AISI4140 steel
by using CBN inserts.
According to their
research, the surface
roughness variation is
mainly dependent on
workpiece hardness
whereas speed does not
play a critical role. They
also concluded that in a
range of 35 to 55 HRC as
the hardness of the
workpiece is increased the
surface finish also
increases, but further
increase in hardness
deteriorates the surface
finish.

17. Experimental study on B. Tulasi Rama Rao, Dr. Stainless steel and In their research, they
the effects of cutting K. Srinivas, Dr. P Ram aluminum experimented with various
parameters on surface Reddy, A. Raveendra, Dr. combinations of three
finish obtained in CNC B. V. R. Ravikumar different parameters
turning operation. namely spindle speed,
depth of cut, and feed rate.
They came to a
conclusion that minimum
surface roughness is
obtained in stainless steel
and aluminum when the
spindle speed is 1200 rpm
and 800 rpm respectively.
Also, they concluded that
as the surface roughness
increases the surface
finish decreases.

18. Cutting temperature: Marcio Bacci da Silva, They stated that out of
prediction and James Wallbank force, surface roughness,
measurement methods chip

dimensions, strain, tool

wear, and temperature, the
temperature is the most
difficult to measure. As
 the temperature is mainly
dissipated at the tool-chip
interface thus the best
method to measure
temperature is by using
the tool-work
thermocouple. It gives the
trends of temperature with
different cutting
parameters like cutting
speed, feed rate, and depth
of cut. They stated that the
application of cutting fluid
to the system adds more

difficulty with the

problem of measuring
temperature.

19. Heat generation and N. A. Abukhshim, P. T. They stated that the best
temperature prediction in Mativenga, M. A. Sheikh technique for measuring
metal cutting: a review temperature is fiber-optic
and implication in high- pyrometers and infrared
speed machining thermography. They also
stated that due to the
complexity of
deformation in the HSM
process, pure analytical
approaches are restrictive.
They concluded that
though there are FE
models for numerical
model analysis of HSM
processes, they also have
some issues which can be
resolved by altering some
of the FE codes.

20. Effect of material Sudesh Garg, Ravi Kumar AISI H11 die steel They concluded that to
removal rate (MRR) on Goyal, Ankit Chabra acquire mail surface finish
AISI H11 die steel in of workpiece, the cutting
drilling using face centred speed should be as high as
design possible and the feed rate
should be as low as
possible.increase in
spindle speed and feed
leads to increase in MRR
 but the depth of hole has
no effect on MRR. They
developed a MRR
prediction mathematical
model that shows that
feed is the most
significant factor affecting
the MRR in drilling
operation.

CHAPTER 3

REVIEWS LITERATURE: -

[1] Patrick Adebisi Olusegun Adegbuyi; Ganiyu Lawal; Oluwatoyin Oluseye;

Ganiyu Odunaiya analyzed the effect of cutting fluid on thermal behavior of the
tool, using different types of fluid at different cutting parameters. In this work soluble
oil, water and palm kernel oil were used as coolants in turning operations. Tungsten
carbide and HSS cutting tools were employed as cutters with cutting speed of
355rpm. Turning was done under dry condition and also using 3 coolants.
Temperature and Hardness values after each cut were recorded. The microstructure of
all the specimens was also done and recorded. It was revealed that variation in the
Hardness value of the samples with progress in machining time is more with the use
of carbide tool compared to the HSS cutter. Samples cooled with water exhibited the
highest hardness value. Palm kernel oil performed very well the specific functions of
soluble oil as cutting fluid which includes good chip formation, reduction of heat
generated and realization of a good surface finish The analysis are shown in tabular
and graphical form in chapter 4 and 5.

[2] T.S. Ogedengbe , A. P. Okediji1, A. A. Yussouf O. A. Aderoba , O.

A.Abiola1, I. O. Alabi1 and O. I. Alonge investigated in dry and wet machining
conditions and their effect on tool temperature profile i.e. effect in their rake face and
temperature distribution on the tool according to the machining conditions and he
concluded that the heat generated could reduce the magnitude of the cutting forces
leading to reduction in power consumption and then improve the machinability of
workpiece. The heat generated during machine operations also affects the material
surface roughness significantly as there is a direct relationship between the two. High
values of surface roughness could result in an eventual failure of parts fabricated.
Tool life reduces with an increase in heat generation during machine operations.
Coolants play a pivotal role in reducing the rate of heat generation in machining.
However, it might still pose a challenge if not well applied. The analysis and
methodology
are shown in tabular and graphical form in chapter 4 and 5.

[3] N.A. Abukhshim, P.T. Mativenga, M.A. Sheikh's work is precisely directed
towards the heat generated during the orthogonal machining process. The emphasis is
on the comparability of test results, as well as, the relevance of temperature
measurement method to high speed cutting. New temperature measurement results
obtained by a thermal imaging camera in high speed cutting of high strength alloys
are also presented. Finally, the latest work on estimation of heat generation, heat
partition and temperature distribution in metal machining is reviewed. This includes
an exploration of the different simplifying assumptions related to the geometry of the
process components, material properties, boundary conditions and heat partition. Set
up ,methodology and result shown in chapter 4 and 5.

[4] Adeel H. Suhail, N. Ismail, S.V. Wong and N.A. Abdul Jalil done his research
in following way-
Approach: The focus of present experimental study is to optimize the cutting
parameters using two performance measures, workpiece surface temperature and
surface roughness. Optimal cutting parameters for each performance measure were
obtained employing Taguchi techniques. The orthogonal array, signal to noise ratio
and analysis of variance were employed to study the performance characteristics in
turning operation.
Results: The experimental results showed that the workpiece surface temperature
can be sensed and used effectively as an indicator to control the cutting performance
and improves the optimization process.
Conclusion: Thus, it is possible to increase machine utilization and decrease
production cost in an automated manufacturing environment.

[5] Sandip Patil, Shital Jadhav, Swapnil Kekade , Ashish Supare, Amit Powar ,
Dr. RKP Singh Machining of titanium alloys generates enormous amounts of heat at
the chip-tool interface leading to poor machinability. The current research
investigates the effect of dry machining of Ti6Al4V on surface integrity of machined
workpiece.
A change in subsurface deformation was assessed by varying cutting speed and feed
rate keeping the cut depth constant. Various output responses viz. cutting
temperature, surface finish, induced strain, deformed depth, microhardness, etc. were
discussed to evaluate the surface integrity. An optical microscopy, SEM and EBSD
analysis performed on the machined edge showed deformation induced damage with
microstructural restructuring which was correlated with chip microstructure. At lower
cutting parameters, work hardening phenomenon however; at high cutting parameters
thermal softening phenomenon becomes more dominant. This was derived with
increased surface roughness, reduction in microhardness values beneath the machined
surface and coarse microstructure obtained at higher cutting parameters. A Chip
microstructural analysis validates the thermal softening and work hardening
phenomenon where at high cutting speeds and feed rate the shear band formation is
accompanied with increased chip segmentation frequency. However, at lower cutting
parameters the reduction segmentation frequency and more deformed grains near the
shear band were observed. The results that were obtained are: An increase in the
cutting speed from 40 m/min to 140 m/min and an increase in the feed rate from 0.2
mm/rev to 0.5 mm/rev lead to higher cutting temperature at the cutting zone because
of enhanced contact between tool and workpiece and hence increased friction. At
lower cutting parameters, work hardening phenomenon however; at high cutting
parameters thermal softening phenomenon was found to be more dominant. This was
derived from increased surface roughness and reduction in microhardness values
beneath the machined surface along with coarse microstructure obtained at higher
cutting parameters. With the increase in level of cutting parameters from Experiment
1 to Experiment 4, depth of deformed grains beneath the machined surface and the
corresponding strain in those deformed grain was found to be increased.

Table 1.- different cutting parameters

[6] Junzhan Hou, Ning Zhao, and Shaoli Zhu done investigation on Influence of
Cutting Speed on Flank Temperature during Face Milling of Magnesium Alloy
Find out that Chip ignition is one of the important problems in cutting magnesium
alloy due to cutting temperature rise, which is mainly caused by the increase of
cutting speed. In this article, we measured the mean flank temperature through
mounting two K-type thermocouples in workpiece of AM50A magnesium alloy.
Effect of cutting speed on the temperature rise of tool flank was analyzed. The results
show that the temperature first increases and then decreases as the cutting speed
increases. The chip ignition appears when the mean flank temperature rise is about
3_C in cutting magnesium alloy at ambient temperature. However, the ignition
cannot be observed with further increase in temperature. The results can
reasonably be used to predict and avoid the occurrence of chip ignition. The analysis
and methodology are shown in tabular and graphical form in chapter 4 and 5.

[7] In this research work the tool-chip interface temperature is measured

experimentally during turning of EN-31 steel alloy with tungsten carbide inserts
using a tool-work thermocouple technique. First and second order mathematical
models are developed in terms of machining parameters by using the response
surface methodology on the basis of the experimental results. The results are
analyzed statistically and graphically. The metal cutting parameters considered are
cutting speed, feed rate, depth of cut and tool nose radius. It can be seen from the first
order model that the cutting speed, feed rate and depth of cut are the most
significantly influencing parameters for the chip-tool interface temperature followed
by tool nose radius. Another quadratic model shows the variation of chip-tool
interface with major interaction effect between cutting speed and depth of cut (V*D)
and the second order (quadratic) effect of cutting speed (V2 ) appears to be highly
significant. The results show that increase in cutting speed, feed rate and depth of cut
increases the cutting temperature while increasing nose radius reduces the cutting
temperature. The suggested models of chip-tool interface temperature adequately
map within the range of the cutting conditions considered. The results and
calculations were shown in chapter 4 and 5.

[8] L. B. Abhang, and M.Hameedullah. in this research paper the measurement of

temperature is done experimentally using tool-work thermocouple technique during
the turning operation of EN31 steel alloy with tungsten carbide. By using the
response surface methodology the first and second order mathematical models are
developed in terms of machining parameters,then statistical and graphical analysis
done. Cutting speed, feed rate, depth of cut and tool nose radius are the main cutting
parameters considered in this research paper.
The first order mathematical model clearly predicts that the chip-tool interface
temperature is mainly affected by the cutting speed, feed rate and depth of cut. The
tool nose radius has the least effect on the chip-tool interface temperature. Another
quadratic model signifies the chip-tool interface variation with cutting speed and
depth of cut. The results collected states that the cutting temperature increases with
increase in cutting speed, feed rate and depth of cut but decreases with decrease in
tool nose radius.
[9] A.G.F. Alabi, Ph.D.; T.K. Ajiboye, Ph.D.; and H.D. Olusegun, Ph.D. his work
is on medium carbon steel subjected to various forms of heat treatment operations, by
assessing the temperature distribution during the machining process. The model of
oblique band heat source, moving in the direction of cutting in an infinite medium
with an appropriate image heat source, was used in this investigation. The model
analysis was carried out separately on the chip, the tool, and the work material, to
numerically determine the temperature distribution during the machining process
using Finite Element Method with nodal grids at the end he concluded that In this
study, Finite Element Modeling was utilized to simulate the temperature distribution
for orthogonal cutting of medium carbon steel subjected to various form of heat
treatment operations. Based on the materials’ properties obtained from the
stress/strain analysis, the annealed specimens gave a better machining condition,
within the selected machining variables as compared to tempered, normalized,
hardened, and the untreated. The modification of the grain structures during the heat
treatment processes were observed to be responsible for these improved machining
properties. The developed model gave a satisfactory result for the simulation of the
chip formation and the development of the temperature distributions in the tool, chip
and the workpiece. Very high and localized temperatures were observed for all the
samples at the tool-chip interface due to a detailed friction model and the shearing
action within the zone. The temperature profile along the shear plane.

[10] Sushil D. Ghodam Temperature at the cutting point of the tool is a crucial
parameter in the control of the machining process. Due to advancement in the
machining processes, a special attention has been given on the life of a tool. To
achieve this, the best way is to apply the coating to the tool. In this study, coated and
uncoated tungsten carbide tools were used and temperature occurred during
machining were measured. Among the number of temperature measuring methods,
the tool-work thermocouple technique is used as it is easy to install and inexpensive
as compared to other methods. He pointed out that generation of high temperature at
the tool rake face takes place due to the enormous frictional forces caused at the tool-
chip interface. This generation of heat can be resisted by using a coated tool.
Reduction in the temperature of the tool improves the tool strength and also improves
the surface roughness of the work piece. From his experimental data, it is found that
as compared to uncoated tool the coating of the tool increases the life of a tool for the
same cutting velocity or for the same tool life, coated tool can be used at higher
cutting speed as compared to uncoated tool.

[11] Abdil Kus, Yahya Isik, M. Cemal Cakir, Salih Coşkun and Kadir Özdemir
in their research paper they estimated the tool-chip interface temperature by
simultaneously employing K- type thermocouple and Infrared pyrometer. As the
machining process is a bit complex thus the researchers insisted on the integration of
two measurement techniques to obtain consistent temperature data. The results from
the thermal analysis were compared through the ANSYS finite element method. The
research was based on dry machining processes using workpiece material of AISI
4140 alloy steel 50 HRC. A PVD TiAlN-TiN-coated WNVG080404-IC907 carbide
insert was used during the turning process. They concluded that cutting speed, feed
rate and depth of cut are the main parameters affecting the cutting tool temperature.
The cutting speed was found to be the most assessing parameter in increasing the
chip-tool interface temperature.

[12] Vamsi Krishna Mamidi and M. Anthony Xavior. This research paper mainly
focuses on different ways by which the tool temperature can be minimised in order to
increase tool life. They stated that using coated cutting tools is a bit expensive and is
only suitable for machining of some materials like titanium alloys, etc. Another way
of minimising the tool temperature is by applying cutting fluids in between the
machining operation, the cutting fluid acts as a lubricant and coolant for the tool
material and the workpiece. They concluded that the most important thing is the
selection of cutting fluid. The selection of cutting fluid should be such that optimum
and economical results are produced in the machining process.

[13] A.A. Sri Rama Krishna, Dr.P.Ravinder Reddy. This research paper deals
with the temperature measurement in machining new materials. The experiment
consists of turning operation on Aluminum 6160- based metal matrix composite with
K-20 carbide cutting tool. The temperature measurement was done along the cutting
tool edge by placing various thermocouples at different cutting speeds and depth of
cuts while the feed rate was kept constant. They modeled a normally loaded
particulate metal matrix composite against a tungsten carbide cutting tool using FEA.
Analytical calculations of heat generation at chip-tool interface, frictional heat
generation at the tool flank and heat generation at the work tool interface were done
and those values were used as boundary conditions. The analysis of steady state heat
transfer was carried out and the temperature distribution at cutting edge, shear zone,
and interface regions has been reported.

[14] Mr. Lathiya Dharmeshkumar and Mr. Viswakarma Ajay. This Research
paper focuses on the determination of maximum temperature during the machining
process and its distribution along the rake surface and their influence on tool life and
quality of machined parts. This work focuses on the various analytical and numerical
analysis of temperature distribution along the rake surface of the tool. An analytical
thermal model was developed to determine the temperature during the cutting
process. The model was developed using MATLAB software.
[15] Özel, T., & Karpat, Y. This research paper mainly focuses on utilising the
neural network modelling in order to predict the surface roughness and tool flank
wear during the machining operation for different conditions in hard turning. Process
specific parameters are also captured using regression models. The neural networks
were trained using different sets of collected data for surface roughness. these trained
neural networks were used in order to determine surface roughness and tool flank
wear at other conditions. In comparison to regression models the predictive neural
networks were found more capable of better predictions. They concluded that
decrease in feed rate gave a better surface roughness but the tool wear was taking
place at a faster rate, whereas increasing the cutting speed resulted in significant
increase in tool wear development but resulted in better surface roughness. Increasing
the hardness resulted in better surface roughness but higher tool wear. Overall they
concluded that CBN inserts with honed edge geometry performed better in both,
better surface roughness and less tool wear.

[16] Chavoshi, S. Z., & Tajdari, M. This research paper is a study of the influence
of hardness and spindle speed on surface roughness in hard turning operation of AISI
4140 using CBN cutting tool. Multiple regression analysis based on analysis of
variance is done in order to find the influence of hardness and spindle speed.
Artificial neural networks and regression methods have been used for modelling of
surface roughness during hard turning. The results indicate that the reverse ANN
model can predict hardness for the train data and spindle speed for the test data with a
good accuracy but the predicted spindle speed for the train data and the predicted
hardness for the test data don’t have acceptable accuracy.

[17] B. Tulasi Rama Rao, Dr. K. Srinivas, Dr. P Ram Reddy, A. Raveendra, Dr.
B. V. R. Ravikumar. This paper deals with studying the optimal surface roughness
in order to get minimum surface roughness. The effect of various cutting parameters
such as cutting speed, depth of cut and feed rate were taken into consideration during
this research. They came to a conclusion that minimum surface roughness is obtained
in stainless steel and aluminum when the spindle speed is 1200 rpm and 800 rpm
respectively. Also, they concluded that as the surface roughness increases the surface
finish decreases.

[18] Marcio Bacci da Silva, James Wallbank. They stated that out of force, surface
roughness, chip dimensions, strain, tool wear, and temperature, the temperature is the
most difficult to measure. As the temperature is mainly dissipated at the tool-chip
interface thus the best method to measure temperature is by using the tool-work
thermocouple. It gives the trends of temperature with different cutting parameters like
cutting speed, feed rate, and depth of cut. They stated that the application of cutting
fluid to the system adds more difficulty to the problem of measuring temperature.

[19] N. A. Abukhshim, P. T. Mativenga, M. A. Sheikh They stated that the best

technique for measuring temperature is fiber-optic pyrometers and infrared
thermography. They also stated that due to the complexity of deformation in the
HSM process pure analytical approaches are restrictive. They concluded that though
there are FE models for numerical model analysis of HSM processes, they also have
some issues which can be resolved by altering some of the FE codes.

[20] Sudesh Garg, Ravi Kumar Goyal, Ankit Chabra. They concluded that to
acquire mail surface finish of workpiece, the cutting speed should be as high as
possible and the feed rate should be as low as possible.increase in spindle speed and
feed leads to increase in MRR but the depth of hole has no effect on MRR. They
developed a MRR prediction mathematical model that shows that feed is the most
significant factor affecting the MRR in drilling operation.

Chapter 4: Methodology

[1] The research work was carried out at the metallurgy workshop. Two of the cutting
fluids (water and soluble oil) with the cutting tools (Tungsten carbide and HSS) were
both obtained from the workshop. The other cutting fluid (palm kernel oil) and the
workpiece (mild steel) were sourced locally. The experiment was carried out on a
center lathe machine. The workpiece was inserted into the 3-jaw chuck and the jaws
were tightened down until the jaw started to grip the workpiece. The Tungsten
Carbide cutting tool was tightly clamped in the tool holder and the angle of the tool
holder was adjusted so that the Tungsten Carbide tool was approximately
perpendicular to the side of the workpiece. The cutting speed was set to 355 rpm and
the laboratory attendant assisted in turning the carriage handwheel counter clockwise
to slowly move the carriage towards the headstock while I continued to apply the
cutting fluid with the help of a hand pump. The process was repeated continuously
until a certain diameter for the workpiece was reached. The diameter of the
workpiece was also determined using a vernier caliper. These steps were repeated for
subsequent cutting fluids while a set was cut dry and after the results of the four
samples had been derived using the Tungsten Carbide cutting tool, the overall
process was repeated using the HSS cutting tool. The cutting temperatures were also
taken immediately after each cutting and the values are shown in the table.
value for each experiment was derived from the

mathematical expression stated below:

Where:

F = 9800N (load factor)

D = 15mm (diameter of steel ball)

d = diameter of indentation (mm)

result and conclusion were discussed in chapter 4 and 5

[2] Dry Machining Condition- It is a situation where no lubricant is used but this is
advisable for milling but not for drilling. It could be used in turning
operation if hard cutting technology is present in the industry. Hard cutting is the use
of hard cutting tools like diamond and Cubic Boron Nitride. These are expensive
tools, but the technology produces some great advantages. Dry machining requires no
coolants hence the working environment is cleaner and more comfortable eliminating
the possibility of slippage during machining.
Wet Machining Condition-Here, both the tool and the workpiece require the right
quantity of coolant. Under wet machining, the heat generated and chip removal rates
occur at the same time Tools utilized here are either externally or internally cooled,
depending on the machining process and the workpiece material. Cooling fluid fed by
the pump also carries away chips produced during the cutting process. The
application of coolant during machining reduces friction between the two surfaces
thereby improving machinability
EXPERIMENTAL SETUP-
Cryogenic Machining
Cryogenic cooling is a cooling type that delivers liquid nitrogen of low temperature
(up to -195oC) directly to the cutting edge to facilitate faster processing speeds and
improve tool life compared to conventional cooling methods. It is an alternative to
conventional machining processes. In the past, this technology was difficult and
costly since it was focused on spraying the liquid nitrogen all over the tool rather than
on the selected cutting edge. The implication was, the coolant will almost evaporate
completely before it gets to the cutting surface, this reduces the ability of cutting and
cooling too. Today, the technology enables the nitrogen to be delivered on the cutting
surface which means the evaporation takes place close to the cutting edge, cooling it
beyond its conventional cutting limits and at the same time increasing the wear
resistance which implies longer life span of the tool . Although, reduced wear on the
cutting edge, increased cutting tool lifespan and increased processing speed are major
advantages of cryogenic cooling, the gases may explode
Hence handling and storage of cryogenic gases can be dangerous.

Fig.3a- CNC milling machine set-up

[3] The ThermaCAM SC3000 was set up and the location of the analysis area was
chosen to be on the chip. The camera was positioned at a distance of 10 mm from the
tool workpiece interface in order to avoid any damage by the chips. The stored
images were recalled and analysed by using the ‘flying spot meters and the line’ in
the software, see program interface in Fig. 3. When placed on the image the
spotmeter gave the temperature value at a particular point and was used to predict the
position of the maximum temperature, while the line gave the maximum temperature
along the tool-chip interface. The line was positioned at a distance of 40 mm from the
interface into the chip as shown in Fig. 4 .
Fig. 3. The Therma CAM researcher main window.

[6] The experimental conditions can be determined according to the industrial

applications. The spindle speed is the common parameter in practical production for
facilitating operation. High cutting speed can be achieved when machining the
magnesium alloy. The up milling was selected in the experiment. The tool holder has
five inserts, as shown in Fig. 3. The angle of engagement in the cut is 120_ , and thus
there are two tool inserts engaged in the cut. In this experiment the cutting speed was
changed from 151 m/min to 3014m/min (spindle speed: 600 rpm, 1000 rpm, 2000
rpm, 4000 rpm, 6000 rpm, 8000 rpm, 10000 rpm, and 12000 rpm); 12000rpm is the
maximum spindle speed of computer numerical control (CNC) milling machine. The
feeding speed was usually fixed at 60mm/min, 100mm/min, 200mm/min,
400mm/min, 600mm/min, 800mm/min, 1000mm/min, and 1200mm/min for
facilitating operation. Therefore, the feed rate of 0.02 mm/tooth was adopted in the
experiment.
Figure 4 shows the experiment setup for the purpose of temperature measurement.
Magnesium alloy workpiece was milled by a CNC milling machine (Mazak FJV-
250). The diameter of the indexable face milling cutter was 80 mm. Tool insert was
K110M of kennametal carbide. Thermocouples 1 and 2 were used to measure the
mean flank temperature. They were mounted in the workpiece, which is located at the
spindle axis of the milling cutter. The distance between thermocouple 1 and cutting
start point was 20mm. The distance between thermocouple 1 and 2 was 110mm.
Diameters of the thermocouple and hole were 1mm and 1.2mm, respectively. A data
logger with 8 channels TC-08 and Pico software were used to record the output data.

Table 3.—Experimental parameters.

Cutting speed 151 m/min–3014m/min
Feed rate 0.02 mm/tooth
Depth of cut 15 _um
Width of cut 60mm
Cooling and lubricating Dry

Figure 3b.—Experimental setup for measuring temperature during face milling

AM50A magnesium alloy (color figure available online)

[11] The Taguchi L18 (21 × 37) method was used for the determination of optimum
control factors. Low, medium and high cutting parameters were selected for the
experiments. In the selection of these parameters, the tool manufacturers’
recommendations and the machine tool capacity were taken into consideration. There
were 18 (3 × 3 × 2) combinations of the turning tests in total which were all carried
out to complete the experiments. The experimental conditions are shown in Table
below:

[13] A thermocouple was used to measure the temperatures at

three different points on the cutting tool. The thermocouple consisting of a sensor
was placed at the chip tool junction and it served as the hot junction. The
room temperature (i.e., the ambient temperature), was taken as the cold
junction. A filter circuit was designed and used to amplify the obtained
electromotive force values as these were too small to be detected by the voltmeter
(multimeter). The schematic diagram of thermocouple setup and circuit
diagram of filter circuit is shown in Figs

The schematic diagram of thermocouple setup and circuit diagram of filter

circuit is shown in Fig.3d.
 Chapter 5: Implementation
Learning from subjects namely Production technology and Heat transfer have helped
me a lot throughout this project as many formulae and theories were used to calculate
the measurement of heat and its calculations so that optimum heat reduction and
efficiency can be obtained.

Theories applied from Production technology: -

Manufacturing Engineering focus on the design and operation of integrated
systems for the production of high-quality, economically competitive products. These
systems may include computer networks, robots, machine tools, and materials-
handling equipment. The cutting process generates heat at the tool and workpiece
interface, generation of heat due to many reasons. The main reason is friction due to
friction heat generated according to the speed of spindle, depth of cut and feed rate.
This heat causes wear and tear in the tool and also reduces the tool life. A researcher,
Taylor's, developed a relation between velocity and temperature and measured the
tool life. Taylor’s tool life equation, VTn=C.

Chapter 6: Results and Analysis

[1]. ANALYSIS OF RESULTS/DISCUSSION AND CONCLUSION

Table 4-THE VARIATION OF TEMPERATURE OF THE WORKPIECE USING

DIFFERENT CUTTING FLUIDS ON A LATHEMACHINE-

SPECIMEN CUTTING CUTTING SPEED TEMPERATU

RE
TOOL FLUID (RPM)
AFTER
TURNING

(oC)
1 HSS WATER 355 34

2 HSS DRY 355 36

 CUTTING
3 HSS PALM 355 35
KERNEL OIL

4 HSS SOLUBLE 355 33

OIL

5 HSS WATER 355 33

6 HSS DRY 355 38

CUTTING

7 HSS PALM 355 38.5

KERNEL OIL

8 HSS SOLUBLE 355 32

OIL

Ambient temperature = 30oC

 Fi
g 4.a: Graph of temperature variation during cutting and cooling for HSS cutting tool
 Fi
g 4.b: Graph of temperature variation during cutting and cooling for carbide cutting
tool

Table 4.1-THE HARDNESS OF MILD STEEL USING DIFFERENT CUTTING

FLUIDS IN A TURNING OPERATION BASED ON THE BRINELL HARDNESS
TEST

SPECIMEN CUTTING CUTTING DIAMETER BRINELL

OF
TOOL FLUID HARDNESS
INDENTATI
ON(d/mm) (N/m2)
1 HSS WATER 2.40 210
2 HSS DRY 2.45 201
CUTTING
3 HSS PALM 2.55 186
KERNEL OIL
4 HSS SOLUBLE 2.55 193
OIL
5 CARBIDE WATER 2.50 186
6 CARBIDE DRY 2.55 193
CUTTING
7 CARBIDE PALM 2.65 186
KERNEL OIL
8 CARBIDE SOLUBLE 2.70 172
OIL

Fi
g 4.c: Hardness values for HSS cutting tool in different medium of cooling
 Fi
g 4d: Hardness values for carbide cutting tool in different medium of cooling

MICROGRAPHIC STRUCTURE OF VARIOUS SPECIMEN-

SPECIMENS

1- 2-

Fig 5a Specimen using dry cutting and carbide cuttingtool Fig5b Specimen using
water as cutting fluid and carbide cutting tool
Fig.5c-Specimen using palm kernel oil as cutting fluid and carbide tool Fig.5d-
Specimen using dry cutting and HSS cutting tool

When cutting fluid applied over the during machining process then it will remove the
heat on the interface of the tool. It will increase tool life and power consumption;
fluid also minimizes the friction coefficient because it acts as a lubricating agent and
also decreases the tool tear and wear during machining process so that proper
dimension and surface finish can be achieved properly.

[2] Effect of heat generated on cutting tool-

Figure6a: Tool life comparison for steel in wet and dry conditions

Modelling of heat distribution on cutting tool-

With the help of Ansys software we created a virtual environment and conducted a
test and following results are observed.
Table 6: Cutting Temperature during machining in various conditions
Run Cutting Temperature (oC)

Tungsten Carbide (T.C) High Carbon Steel

(HCS)

Dry Wet Cooled Dry Wet

Cooled

1 909 301 62 547 233 72

2 863 277 55 456 188 70

3 780 270 44 401 166 65

4 652 264 32 373 144 58

5 620 234 24 350 125 55

RESULT-1. The heat generated could reduce the magnitude of the cutting forces
leading to reduction in power consumption and then improve the machinability of the
workpiece.

2. The heat generated during machine operations also affect the material surface
roughness significantly as there is a direct relationship between the two. High values
of surface roughness could result in an eventual failure of parts fabricated

3. Tool life reduces with an increase in heat generation during machine operations.
Coolants play a pivotal role in reducing the rate of heat generation in machining.
However, it might still pose a challenge if not well applied.

[3] temperature prediction and distribution models: -

Fig 5e- chip tool interface modeling, fig. 5f- temperature
distribution at different time.

Maximum tool-chip interface temperatures were found to be 700 and 1000 8C for
cutting speeds of 122 and 244 m/min, respectively and a depth of cut of 0.25 mm.
The location of the maximum interface temperatures occurred approximately at the
mid of the contact length.

[6] Mean Flank Temperature Measurement

In face milling, both major tool-flank and minor tool flank can cut the thermocouple
simultaneously. We call the measured temperature as mean flank temperature
hereinafter. The measurement process is shown in Fig. 5. The thermocouple contacts
one side of hole. This arrangement is more sensitive to measure temperature than that
of the case that the thermocouple does not contact any side of hole . As the cutter
moves ahead, the thermocouple is heated by the shear plane until the top of the
thermocouple is cut-off. The measured temperature reaches maximum when the
major and minor tool flank passes over the thermocouple. The observed maximum
temperature is the mean flank temperature, which is mainly generated by the heating
in the shear plane and tool-work friction. The measured temperature is low because
the thermocouple gives a mean value. Figure 6(a) shows the temperature output
results of Pico software when the cutting speed is 151 m/min. There are two
temperature pulses A and B obtained from thermocouples 1 and 2, respectively, and
amplitude of pulse B is higher than pulse A. Figure 6(b) shows that there are four
temperature pulses generated when The cutting speed is 1005 m/min. Pulses C and D
were obtained by thermocouple 1. Pulses E and F were achieved by thermocouple 2.
Insert pictures in Fig. 6(b) show the relative position between cutter and
thermocouple. Pulses C and E can be obtained when the front end of the milling
cutter passes over the two thermocouples. They are the same as the results shown in
Fig. 6(a). Pulses D and F may be generated by the back end of the milling cutter. To
explore this phenomenon shown in Fig. 6(b), we observed the tool tip using a
scanning electron microscope (SEM). As can be seen from Fig. , adhesion appears on
the rake face, major and minor flank. And the adhesion also exists on the cut edge.
This may lead to the temperature pulses of D and F, as shown in Fig. 6(b). It is
generally consistent with the report that the critical cutting speed at which flank
build-up occurs is about 900m/min.

Figure 5.f.—The schematic diagram of temperature measurement in face

Figure 5g.—The temperature obtained using the two thermocouples under different
cutting speeds: (a) cutting speed = 151 m/min and (b) cutting speed = 1005 m/min,
insert pictures are the relative position between cutter and thermocouple.
[11] Relationship between cutting parameters and heat distribution

Temperature measurement was done simultaneously during this experiment and

the results achieved are provided in the table below:
 TABLE: EXPERIMENTAL RESULTS

Effect of machining time on tool temperature:

The effect on temperature was observed during the processing time of the cutting
process. This was due to the tool wear and friction at the cutting zone. The graph
below shows variation of tool temperature with the time at different cutting speeds
and feed rates.

FIG: Change of tool temperature during cutting process depending on time

Cutting speed and feed rate are also the main factors influencing the tool
temperature although increasing the cutting speed helps to reduce friction at tool
flank but the tool temperature increases rapidly as shown in figures below.
 FIG: Influence of cutting speed and feed rate on tool temperature

The tool chip interface temperature increases by upto 30% as the cutting speed is
increased, but the change in feed rate barely has any effect on the tool-chip
interface temperature. The influence of feed rate and cutting speed on tool-chip
interface temperature is shown in figure below:

FIG: The influence of feed rate and cutting speed on tool-chip interface temperature

Finite element model:

It is possible to evaluate the heat distribution into the cutting tool by employing a
FEM model, reducing the available heat flux until the simulated temperature
matches with the experimentally measured temperature. Figure below shows the
temperature distribution of between 29.89 °C and 412.9 °C on the tool-chip
interface as well as the temperature distribution along the 12 mm path that starts
from the tool-chip interface.

FIG: Temperature distribution on the path from the tool chip interface

Chapter 6: Conclusion
 REFERENCES

[1] Patrick Adebisi Olusegun Adegbuyi, Ganiyu Lawal, Oluwatoyin Oluseye, Ganiyu Odunaiya.
(2015). A Review on Heat Generation in Metal Cutting, 5(4), 193-197.
[2] [2] Ogedengbe T.S., Abdulkareem S. and Aweda J.O. (2018). Effect of Coolant Temperature on
Machining Characteristics of High Carbon Steel. Covenant Journal of Engineering
Technology. Volume 1.73-86.
[3] Bahmani M, Elliott R, and Varahram N, Int J Cast Met Res 9(1997) 249.
[4] A A Latif, M R Ibrahim*, A Z Amran, and E A RahimIOP Conf. Series: Materials Science and
Engineering 257 (2017) 012025 doi:10.1088/1757-899X/257/1/012025
[5] Figure 2,3. Sodick MC430L , Cutting tool-Conventional NOVIANO] A A Latif, M R
Ibrahim*, A Z Amran, and E A RahimIOP Conf. Series: Materials Science and Engineering 257
(2017) 012025 doi:10.1088/1757-899X/257/1/012025.
[6] Arunachalam, R. M., Mannan, M. A., & Spowage, A. C. Residual stress and surface roughness
when facing age hardened Inconel 718 with CBN and ceramic cutting tools. International Journal of
Machine Tools and Manufacture, 44(9), 879-887, 2004
[7] Ogedengbe, T.S., Awe P. and Joseph O. I. (2019). Comparative Analysis of Machining
Stainless Steel using Soluble and Vegetable oils as Cutting Fluids, International Journal of
Engineering Materials and Manufacture, 4(1), 33-40
[8] Izamshah, R., Husna, N., Hadzley, M., Amran, M., Shahir, M., & Amri, M. 2014 Effects of
cutter geometrical features on machining polyetheretherketones (PEEK) engineering plastic.
Journal of Mechanical Engineering and Sciences, 6, 863-72.
[9] Boujelbene, M., Bayraktar, E., Tebni, W., & Salem, S. B. 2009 Influence of machining
parameters on the surface integrity in electrical discharge machining. Archives of Materials
Science and Engineering, 37(2), 110-116.
[10] Joshi, A., Kothiyal, P., & Pant, R 2012. Experimental investigation of machining parameters
of CNC milling on MRR by taguchi method. International Journal of Applied Engineering
Research, 7(11)
[11] “Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in
Metal Cutting” by Abdil Kus, Yahya Isik, M. Cemal Cakir, Salih Coşkun and Kadir Özdemir.

[12] “A review on selection of cutting fluids” by Vamsi Krishna Mamidi and M. Anthony Xavior.

[13] “Temperature Prediction in Orthogonal Machining of A1/SiCp Composites” by A.A. Sri Rama
Krishna, Dr.P.Ravinder Reddy.

[14] “Temperature rise distribution due to the combined effects of shear plane heat source and
the tool chip interface frictional heat source” by Mr. Lathiya Dharmeshkumar and Mr. Viswakarma
Ajay.
[15] “Predictive modeling of surface roughness and tool wear in hard turning using regression and
neural networks” by Özel, T., & Karpat, Y.

[16] “Surface roughness modeling in the hard turning operation of AISI 4140 using CBN cutting
tool.” by Chavoshi, S. Z., & Tajdari, M.

[17] “Experimental study on the effects of cutting parameters on surface finish obtained in CNC
turning operation.” by B. Tulasi Rama Rao, Dr. K. Srinivas, Dr. P Ram Reddy, A. Raveendra, Dr. B. V.
R. Ravikumar.

[18] “Cutting temperature: prediction and measurement methods” by Marcio Bacci da Silva, James
Wallbank.

[19] “Heat generation and temperature prediction in metal cutting: a review and implication in
high-speed machining” by N. A. Abukhshim, P. T. Mativenga, M. A. Sheikh.

[20] “Effect of material removal rate (MRR) on AISI H11 die steel in drilling using face centred
design” by Sudesh Garg, Ravi Kumar Goyal, Ankit Chabra.

Reference / Hand Books

[1] PN RAO, “Production Technology Tata McGraw-Hill Education, 2013, 4, 1259062570,

9781259062575

Web

[1] Topic 1.a-e, https://www.sandvik.coromant.com/en-

gb/products/pages/drilling-tools.aspx]