Abstract:
The energy dissipated in machining operation is converted into heat which raises
the temperature in the cutting zone. With the increase of cutting temperature; tool wear,
surface roughness, dimensional inaccuracy increases significantly. Cutting force is also
increased with tool wear which results the increase of power and specific energy
consumption. Various researchers worked on various techniques to effectively control the
increased cutting temperature as well as cutting force, tool wear rates, surface integrity.
The cutting temperature, which is the cause of several problems restraining productivity,
quality and hence machining economy, can be controlled by the application of highpressure
coolant (HPC) jet. High-pressure coolant (HPC) jet cooling is a promising
technology in high speed machining, which economically addresses the current processes,
environmental and health concerns.
Based on cutting condition, cutting environment and work/tool material the
physical behavior during metal cutting has been changed. From an economic viewpoint, it
is evident that having knowledge about the machining responses such as tool life, cutting
forces, cutting temperature and work piece surface integrity at different cutting conditions
would be highly desirable as a means of realizing cost savings, increased productivity,
efficiency and for preventing any hazard occurring to the machine, cutting tool or the
deterioration of the product quality. Optimization of process parameters for improving
product quality, shortening processing time and reducing production cost is very important
and for this purpose modeling of process parameters is necessary.
By laborious and costly experimental investigation, machining responses like
cutting temperature, cutting force, tool wear and surface roughness can be measured.
Engineers and researchers have been realizing that efficient quantitative and predictive models that establish the relationship between a big group of input independent parameters
and resultant performance are required for the wide spectrum of manufacturing processes,
cutting tools and engineering materials currently used in the industry could contribute in
industrial applications along with theoretical understanding.
The aim of the present work is to investigate the role of high-pressure coolant jet
in respects of chip formation, cutting temperature and force experimentally and then
develop predictive models for cutting temperature and force in turning medium carbon
steel (AISI 1060 steel) by uncoated carbide insert at industrial speed feed conbinations
under high pressure coolant condition.
The experimental results indicate that the performance of the machining under
HPC condition is quite good and more effective compared to machining under dry
condition. With the help of the experimental results, predictive models of cutting
temperature and force have been developed to understand the basic phenomenon in metal
machining. Prediction of cutting temperature has been conducted from analytical studies,
where empirical correlations have been used to determine heat generation and temperature.
Analytical calculations have been done under simplified assumptions. Using statistical
analysis, predictive models of force has been developed. Finally, finite element model has
been developed to evaluate temperature distribution by ABAQUS/CAE. The developed
models satisfactorily validate its accuracy by comparing predicted values with
experimental values.
