SALEM ABDULLAH BAGABER A COMPARATIVE STUDY ON PERFORMANCE OF CBN INSERTS WHEN TURNING STEEL UNDER DRY AND WET CONDITIONS SALEM ABDULLAH BAGABER August 2017

Total GHG emissions by sector (EU-27, 2011) Characteristics of sustainable machine (Chetan et al. 2015) Total GHG emissions by sector (EU-27, 2011) Power consumption of main functions in machine tools (Götze et al. 2012)

LITERATURE REVIEW

LITERATURE REVIEW

PROBLEM STATEMENT The best technique of environmental machining is dry machining (Dixit et al. 2012; Schultheiss etal.2013). Issues regarding thermal damage to the workpiece are with the dry machining (Iqbal etal.2009). Cooling/lubrication fluids (CLFs) based oil are known one of the most unsustainable elements of machining processes (Pusavec et al. 2010) (King.etal.2001) .

Considering the increase of energy consumption - -Very limited research investigate of machinability includes power consumption often neglected (Nur2015) -Studied rarely(Wang&Wang,2014).Still surveyed by experiments, not given attention (Gupta,2005) -Most important factors among of factors (Yoon et al. 2015), become a topic high on the agenda for manufacturing enterprises (Li 2015). Interplay of energy consumption and other objectives are not clearly understood yet (Li et al. 2016)

The aims of this research is: To evaluate performance of CBN inserts for the machining parameters PW and Ra. Comparative study on PW and Ra under dry and flood conditions

Dry condition apply as environment cutting. This project focuses on the effect of cutting parameters of turning machine. The material used to cut will be specification Stainless Steel 316 (63x120mm). At less Three machine parameters will be varied to the experiments. Namely, cutting speed, feed rate and depth of cut. Dry condition apply as environment cutting. The type of cutting tool has been used coated Carbide tools Design of Experiments (DOE) specify to BBD methods layout will be used for testing with five(5) level and analysing and optimizing using RSM.

The machine used will be CNC turning Machine (ROM-C420) -LCD with Siemens Sinumerik828D CNC programming. A surface roughness will be measured by using a Mitutoyo Surftest SJ-210 portable surface roughness tester. The digital Power Meter KEW6305 will be used to capture the power utilized during the cutting process. Tool wear of the cutting tool will be measured using the high power optical microscope.

Response surface method (RSM) with box-behnken design (BBD) No Factors Symbol type Lowest level Low level mid-level High level Highest level 1 Cutting speed (rpm ) A Numerical (-2) (-1) (1) (+2) 2 Feed rate (mm/min) B 3 Depth of cut (mm) C The max and min value of parameters: Vcmin = 90, Vcmax = 190 m/min frmin = 0.06, frmax = 0.23 mm/rev ap, min = 0.6, ap, max=1.6 mm -adapted from the Karoly handbook -based on rough-finish cuts. -Previous studies studies (Philip Selvaraj et al. 2014; Varaprasad et al. 2014; Berkani et al. 2015; Kara et al. 2014; Nur et al. 2015)

Experimental Equipments d

Mitutoyo tool maker microscope used in the presented research work To investigate this flank wear Power Meter 6300 used to capture the power utilized during the cutting test A surface roughness manufactured measured by using a Mitutoyo Surftest SJ-301

Materials workpiece Cutting tool length 120 mm Ø63 mm properties (high mechanical properties and corrosion resistance) widely used in many industries such as aerospace, components of contracture, automotive, chemical production, power plants, and medical instruments. Researches regarding the machinability of the austenitic stainless steels have highlighted the insufficiency of the data for establishing of the optimum cutting conditions (Sultan et al. 2015). Machinability study on the stainless steel still is of interest (Nur et al. 2015) length 120 mm Ø63 mm Cutting tool Coating inserts carbide was selected. Carbide tools CNMG 120408 - Coated - PVD TiAlN coating designated as ISO CNMG 120408, with 80o diamond sharp. Cutting tools Young’s modulus: –H10, 92.4 +1 HRA 47 (103kgf/mm2) Tool holder: BCLNR2525M12

Collection data &Analysis Experiment setting Collection data &Analysis CBN

Results of the experiment EVALUATION BASED ON LUBRICATION Results of the experiment Std Order Dry Flood PW (Wh) Ra (µm) PW (Wh) 1 32.6 0.478 41.5 0.415 2 35.51 0.965 43.87 0.534 3 25.65 0.64 34.31 0.498 4 30.28 1.331 39.2 0.987 5 34.11 0.491 32.92 0.613 6 37.8 0.924 45.79 0.528 7 23.5 1.37 32.14 1.29 8 22.81 1.104 31.52 1.467 9 36.2 0.845 45.6 0.677 10 35.72 1.245 44.32 11 32.8 1.53 42.04 12 23.9 1.6 32.56 1.225 13 27.8 0.72 36.09 0.814 14 29.81 0.714 38.13 0.726 15 26.5 0.741 34.98 0.711

Effect Compare

Effect Compare

POWER CONSUMPTION (a) (b) (c) PW (W/h) Cutting speed (m/min) Depth of cut (mm) Feed rate (mm/rev) PW (W/h) (b) (c)

SURFACE REGHNESS (a) (b) (c) Ra (µm) Depth of cut (mm) Cutting speed (m/min) Feed rate (mm/rev) Depth of cut (mm) Ra (µm) (a) (b) (c)

Regression model and R-Squr values AdjR-squr PrdR-Squr Energy (dry)= +5.39290-0.29426* v -0.77196 * f -0.21368* d 0.8776 0.8546 0.7906 Energy (wet) = +5.79107-0.26496 * v -0.85629* f-0.14931 * f+0.17433* f2 0.8805 0.8487 0.6707 Ra (dry)= +0.87214+0.0196 * v+0.15506 * f+0.068* d-0.0253 * v2+0.0228 * f2+0.0463* d2+0.0652* v * f -0.0663 * v*d 0.8610 0.7599 0.5631 Ra (wet) = +0.86+0.010* v+0.14* f+0.092 * d-0.015* v2+0.034* f2+0.042 * v * f -0.044* v * d+0.064 * f * d 0.9263 0.8727 0.6894

Energy analysis Start-up power Spindle acceleration power Machining power Pst Pcut Pair P0 Setting-up power

Power (Kw)

Power consumption is affected mostly by feed rate followed by speed and depth of cut. Optimum parameters determined (110m/min, 0.24mm/rev, 1.6mm) for power, for Ra (90m/min, 0.08mm/rev, 0.5mm) and (100m/min, 0.5mm) for TW based on minimum value of energy, tool wear and maximum of quality and tool life. Feed rate, followed by depth of cut, was found to be the most influential factor on Ra The analysis of results on the turning of AISI 316 was performed by using CBN in an environment cutting process with-without fluid. AISI316 can be machined under dry to save energy and environment with acceptable quality compare to the wet condition CONCLUSION

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