(TITLE)

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 (NAME OF THE DEPARTMENT)

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 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

LIST OF FIGURES
Figure Page
No Figure Title No
 Contents
Page No
Acknowledgeme
nt i
Abstract ii
List Of Figures iii
List Of Tables vi
Chapter 1 INTRODUCTION

1.1 Motivation

1.2 Objectives

1.3 Organization of Report

Chapter 2 BACKGROUND MATERIAL
2.1 Conceptual Overview
2.2 Technologies Involved

Chapter 3 - Literature

Chapter 4 METHODOLOGY
3.1 Detailed methodology that will be adopted

Circuit Layouts / block diagrams

3.2

.
.
Chapter 5 IMPLEMENTATION

4.1 Modules

4.2 Prototype

Chapter 6 RESULTS AND ANALYSIS

.
.
.
Last
CONCLUSIONS & FUTURE SCOPE
Chapter
5.1 Conclusions
5.2 Future Scope of Work (at least 3 points)
REFERENCES
ANNEXURES (OPTIONAL)
 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

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. 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, n general, cemented carbide is understood as
WC-Co-based alloy. 1)

1. High hardness

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

abrasion resistance.

2. High strength

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

reliability against forces in bending direction.

3. High rigidity

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. 

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: -

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.

REVIEW PAPERS SEQUENCE SERIES: -

RESEARCH TOPIC AUTHOR TOOL USED RESULT
1.Analysing the Patrick Adebisi HSS and Carbide Straight oils
effect of cutting Olusegun provide the best
fluids on the Adegbuyi, Ganiyu lubrication
mechanical Lawal, Oluwatoyin
but poor cooling
properties of mild Oluseye, Ganiyu
capacities. Water,
Odunaiya
steel in a turning on the other
operation hand,

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 T.S. Ogedengbe, (a) Tungsten– 1. The heat
Heat Generation A. P. Okediji, A. A. Carbide (b) High generated could
on Cutting Tool Yussouf, O. A. Carbon reduce the
and Machined Aderoba, O. A. magnitude of the
Steel
Abiola, I. O. Alabi cutting forces
Workpiece leading to
and O. 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 N.A. Abukhshim, Single point fibre-optic
and temperature P.T. Mativenga, cutting tool pyrometers and
prediction in M.A. Sheikh infrared
metal cutting: A thermography
review and techniques these
implications for techniques could
high speed measure
machining temperature, as
well as, the
cooling rate easily,
accurately and
with fast time
response
4.Optimization of Adeel H. Suhail, N. medium carbon This study
Cutting Ismail, S.V. Wong steel AISI 1020 discussed an
Parameters Based and N.A. Abdul application of the
on Surface Jalil Taguchi method
Roughness and for optimizing the
Assistance of cutting
Workpiece parameters in
Surface turning operations
Temperature in using combined of
Turning Process 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 Heat on Jadhav, Swapnil cutting speed
the Surface Kekade, Ashish from 40 m/min to
Supare, 140 m/min and an
Integrity during
increase in the
Machining of Amit Powa , Dr.
feed rate from 0.2
Titanium Alloy RKP Singh
mm/rev to 0.5
Ti6Al4V
mm/rev lead to
higher 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 Junzhan Hou, Ning Face milling cutter The temperature
Cutting Speed on Zhao, and Shaoli rise increases
Flank Zhu slightly when the
Temperature cutting speed is
less than 1507
during Face
m/min. When the
Milling of
cutting speed is
Magnesium Alloy
up to more than
1507 m/min, the
temperature
increases
significantly.
7. Analyses of Marcelo Ribeiro High speed steel Results are
Effects of Cutting dos Santos, tool discussed in
Parameters on Sandro Metrevelle section.
Cutting Edge Marcondes de
Lima e Silva,
Temperature
Using Inverse Álisson Rocha
Heat Conduction Machado, Márcio
Technique Bacci da Silva,
Gilmar Guimarães,
 and Solidônio
Rodrigues de
Carvalho
8. Chip- tool L. B. Abhang, and High speed steel The appropriate
interface M.Hameedullah tool aggregation
temperature among the cutting
prediction model speed, feed rate,
for turning depth of cut and
process tool nose radius
can generate
minimum cutting
temperature
during steel
turning
9. Investigation of A. G. F. Alabi, T. K. High speed steel The temperature
Cutting Ajiboye and H.D. tool profile obtained
Temperatures Olusegun indicated that the
Distribution in tool has a higher
Machine Heat machining
Treated Medium temperature
Carbon Steel on a when machining
Lathe steel materials.
10. Temperature Sushil D. Ghodam Mild steel He pointed out
measurement of a that generation of
cutting tool in high temperature
turning process by at the tool rake
using tool work face takes place
thermocouple 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. Thermocouple Abdil Kus, Yahya PVD TiAlN-TiN- They concluded
and Infrared Isik, M. Cemal coated that the most
Sensor-Based Cakir, Salih WNVG080404- important in
Measurement of Coşkun and Kadir IC907 carbide reference to tool
Temperature Özdemir chip interface is
Distribution in cutting speed.
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 Vamsi Krishna High-speed steel, They concluded
selection of Mamidi and M. tungsten carbide, that the three
cutting fluids Anthony Xavior cubic boron major factors
nitride, affecting the
polycrystalline cutting fluid are
diamonds, the machining
ceramic and process,
diamond cutting workpiece
tools 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 K-20 carbide They stated that
Prediction in Krishna, cutting tool the maximum
Orthogonal Dr.P.Ravinder temperature that
Machining of Reddy can be found at
A1/SiCp the chip tool
Composites 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 Mr. Lathiya NE 9445 steel and They stated that
rise distribution Dharmeshkumar AISI 1045 steel the quality of
due to the and Mr. with a carbide machined part
combined effects Viswakarma Ajay tool and tool life is
of shear plane mainly influenced
heat source and by the
the tool chip temperature
interface frictional produced at the
heat source 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 Özel, T., & Karpat, hardened AISI H- They used neural
modeling of Y. 13 steel network modeling
surface roughness to predict surface
and tool wear in roughness and
hard turning using tool flank wear
regression and 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 Chavoshi, S. Z., & AISI 4140 using They found the
roughness Tajdari, M. CBN cutting tool effect of spindle
modeling in the speed and
hard turning material hardness
operation of AISI variations on the
4140 using CBN surface roughness
cutting tool. of 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 B. Tulasi Rama Stainless steel and In their research,

study on the Rao, Dr. K. aluminum they
effects of cutting Srinivas, Dr. P Ram experimented
parameters on Reddy, A. with various
surface finish Raveendra, Dr. B. combinations of
obtained in CNC V. R. Ravikumar three different
turning operation. parameters
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 Marcio Bacci da They stated that

temperature: Silva, James out of force,
prediction and Wallbank surface
measurement roughness, chip
methods
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 N. A. Abukhshim, They stated that

generation and P. T. Mativenga, the best
temperature M. A. Sheikh technique for
prediction in measuring
metal cutting: a temperature is
review and fiber-optic
implication in pyrometers and
high-speed infrared
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 Sudesh Garg, Ravi AISI H11 die steel They concluded
material removal Kumar Goyal, that to acquire
rate (MRR) on AISI Ankit Chabra mail surface finish
H11 die steel in of workpiece, the
drilling using face cutting speed
centred design 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 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.

[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.

[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 ThermaCAM 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 1.—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 4.—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
 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

THE VARIATION OF TEMPERATURE OF THE WORKPIECE USING DIFFERENT CUTTING

FLUIDS ON A LATHE MACHINE-

SPECIMEN CUTTING CUTTING SPEED TEMPERATURE

TOOL FLUID (RPM) AFTER

TURNING

(oC)
1 HSS WATER 355 34

2 HSS DRY CUTTING 355 36

3 HSS PALM KERNEL 355 35
OIL

4 HSS SOLUBLE OIL 355 33

5 HSS WATER 355 33

6 HSS DRY CUTTING 355 38

7 HSS PALM KERNEL 355 38.5

OIL

8 HSS SOLUBLE OIL 355 32

Ambient temperature = 30oC

 Fi
g 3.2: Graph of temperature variation during cutting and cooling for HSS cutting tool
 Fi
g 3.3: Graph of temperature variation during cutting and cooling for carbide cutting
tool

THE HARDNESS OF MILD STEEL USING DIFFERENT CUTTING FLUIDS IN A TURNING

OPERATION BASED ON THE BRINELL HARDNESS TEST

SPECIMEN CUTTING CUTTING DIAMETER OF BRINELL

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

Fi
g 3.4.1: Hardness values for HSS cutting tool in different medium of cooling
 Fi
g 3.4.2: Hardness values for carbide cutting tool in different medium of cooling

MICROGRAPHIC STRUCTURE OF VARIOUS SPECIMEN-

SPECIMENS

1- 2-

Fig 1 Specimen using dry cutting and carbide cutting tool Fig2 Specimen using water
as cutting fluid and carbide cutting tool
Fig.Specimen using palm kernel oil as cutting fluid and carbide tool Fig.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-

Figure: 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 1: 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 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

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: -

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.—The schematic diagram of temperature measurement in face

Figure 6.—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

REFERENCES

Journal / Conference Papers

[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.

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 2 Hard Copies to be submitted to project coordinator after Project Guide & HOD’s
signature.

 Soft copy (both word and pdf format) to be submitted in CD with project name,
students name with registration number mentioned on CD cover. Paste this CD on the
last page of your project report and submit to the office of Project coordinator.