International Journal of Advanced Research in and Technology (IJARET) Engineering International Journal of Advanced Research in Engineering and Technology

(IJARET), ISSN 0976 6480(Print) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME ISSN 0976 6499(Online) Volume 2 Number 1, Jan - Feb (2011), pp. 12-28 IAEME IAEME, http://www.iaeme.com/ijaret.html

IJARET

OPTIMIZATION OF SURFACE FINISH DURING MILLING OF HARDENED AISI4340 STEEL WITH MINIMAL PULSED JET OF FLUID APPLICATION USING RESPONSE SURFACE METHODOLOGY
K. Leo Dev Wins School of Mechanical Sciences Karunya University, Coimbatore Tamilnadu, E-Mail: leodevwins@gmail.com A. S. Varadarajan School of Mechanical Sciences Karunya University, Coimbatore Tamilnadu

ABSTRACT
Machining with minimal fluid application is involves the use of extremely small quantities of cutting fluid so that for all practical purposes it resembles dry machining. This technique is free from problems associated with procurement, storage and disposal of cutting fluid and helps in promoting an eco friendly atmosphere on the shop floor. Apart from machining parameters, the fluid application parameters such as pressure of the fluid injector, frequency of pulsing and the rate of fluid application also influence the cutting performance during minimal fluid application. Good surface finish is a functional requirement for many engineering components and in the present investigation an attempt is made to optimize surface finish during milling of hardened AISI4340 steel with minimal fluid application using response surface methodology. The surface finish predicted by the model matched well with the experimental results. Key words: Central composite; Environment friendly; Mathematical models; Minimal cutting fluid application; Pulsed jet; Rotatable design.

1. INTRODUCTION
Conventional surface milling of hardened steel involves application of large quantities of cutting fluid. Procurement, storage and disposal of cutting fluid incur expenses and large scale use of cutting fluid causes serious environmental and health
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

hazards on the shop floor. It also leads to problems in disposal of cutting fluid which has to comply with environmental legislation as well. According to the Occupational Safety and Health Administration (OSHA) regulations, the permissible exposure Level for mist within the plant (PEL) is 5 mg/mand is likely to be reduced to 0.5 mg/m [1]. In this context, pure dry milling is a logical alternative which is totally free from the problems associated with storage and disposal of cutting fluid. But it is difficult to implement on the existing shop floor as it requires ultra hard cutting tools and extremely rigid machine tools [2]. Ultra hard cutting tools may be introduced but the existing machine tools may not be rigid enough to accept them. In this context the best alternative is to introduce pseudo dry milling or milling with minimal fluid application [3 - 6]. By introducing the cutting fluid precisely at the cutting zone, better cutting performance can be achieved which will result in better surface finish, reduction of tool wear and cutting force [79]. In minimal fluid application, extremely small quantities of cutting fluid is introduced as high velocity (70 m/s) tiny droplets at critical zones so that for all practical purposes it resembles dry milling [10]. It is reported that minimal cutting fluid application can bring forth better cutting performance during turning and in the case of minimal application, heat produced during machining is transferred predominantly in the evaporative mode, which is more efficient than the convective heat transfer prevalent in conventional wet turning [3, 10]. Very less work is reported in the area of fluid minimization during milling [11, 12]. Research work carried out in our laboratory indicated that good cutting performance could be achieved in terms of surface finish, tool wear and cutting force when a specially formulated cutting fluid was applied on critical locations in the form of high velocity narrow pulsed jet during surface milling of AISI4340 steel with a hardness of 45 HRC by a fluid application system that can deliver cutting fluid through fluid application nozzles and offer better rake face lubrication. The scheme is environment friendly and can be easily implemented on the shop floor. Surface roughness (Ra) is widely used as an index to determine the surface finish in the machining process. Surface roughness has become one of the important output parameters for many years and one of the important design features in many situations such as parts subject to fatigue loads, precision fits, fastener holes and aesthetic
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

requirements. In addition to the tolerances, surface roughness imposes one of the most critical constraints for selection of machines and cutting parameters in process planning [13]. For achieving the desired surface finish, it is necessary to understand the

mechanisms of the material removal and the kinetics of machining processes affecting the performance of the cutting tool [14]. Earlier work in this research showed the fluid application parameters such as pressure at the fluid injector, frequency of pulsing and the rate of fluid application affects the surface roughness to a larger extent [11]. The

traditional one-factor at a time technique used for optimizing a multivariable system is not only time consuming but often misses easily the alternative effects between the components. Also, this method requires carrying out a number of experiments to

determine the optimum levels, which are false at most of the times. These drawbacks of single factor optimization process can be eliminated by optimizing all the affecting parameters collectively by central composite design (CCD) using Response Surface Methodology (RSM). For prediction, the response surface Method is practical, economical and relatively easy to use when compared to other types of optimization techniques [15]. In the present work, a mathematical model has been developed to predict the surface roughness of machined work piece using response surface method. Analysis of variance (ANOVA) is used to check the validity of the model developed.

1.1 Selection of work material

Through hardenable AISI4340 steel was selected as work material. hardened to It was 45 HRC by heat treatment. It is a general purpose steel having wide range

of applications in automobile and allied industries by virtue of its good hardenability. Plates of 125 mm length, 75 mm breadth and 20 mm thickness were used for the present investigation. The composition of the work material is shown in Table 1.
Table 1 Chemical composition of work material Element % C 0.38 0.43 Cr 0.7 0.9 Mn 0.6 0.8 Mo 0.2 0.3 Ni 1.65 2.0 P 0.035 max Si 0.15 0.3 S 0.04 max Fe Balance 14

International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

1.2 Selection of cutting tool

Carbide inserts with the specification AXMT 0903 PER-EML TT8020 of TaeguTec was used in the investigation along with a tool holder with the specification TE90AX 220-09-L.

1.3 Formulation of cutting fluid

Since the quantity of cutting fluid used is extremely small, a specially formulated cutting fluid was employed in this investigation. The base was a commercially available mineral oil and the formulation contained other ingredients [16]. It acted as an oil in water emulsion.

1.4 Fluid application system

Figure 1 Schematic view of the minimal fluid applicator

A special test rig was developed for this purpose [3]. It consists of a P-4 fuel pump (Bosch make) coupled to an infinitely variable electric drive. An injector nozzle of single hole type with a specification DN0SD151 with a spray angle of 0 was used in the investigation. The test rig facilitated independent variation of pressure at fluid injector (P), frequency of pulsing (F) and the rate of fluid application (Q). The system can deliver cutting fluid through four outlets simultaneously so that cutting fluid could be applied to more than one location or more than one machine tool at the same time. By selecting proper settings the rate of fluid application could be made as small as 0.25ml/min. The frequency of pulsing is determined by the speed of rotation of the DC variable speed motor that drives the fluid pump. The fluid applicator delivers cutting fluid at a rate of one pulse per revolution. This facility enables application of less amount of cutting fluid per pulse. For example, if Q is the rate of fluid application in ml/min and F is the frequency of pulsing in pulses/min, fluid applied per pulse is given by Q/F. Pulsing jet aids in fluid minimization
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without compromising the velocity of individual particles as the pressure at the fluid injector remains constant. By increasing the frequency, the rate of fluid delivered per pulse can be controlled. For example if Q is 1 ml/min and F is 1000 pulses/min and the pressure at the fluid nozzle is set at 100 bar, then fluid delivered per pulse is equal to 1/1000 = 0.001 ml while the velocity of the individual fluid particles will be approximately equal to about 70 m/sec [10]. A schematic view of the fluid applicator is shown in Figure 1. Special fixtures were designed as in Figure 2 so that the injector nozzle could be located in any desired position without interfering the tool or work during actual cutting.

Figure 2 Fixtures for locating the fluid injector

2. SCHEME OF INVESTIGATION
The experiments were designed based on five-level factorial central composite rotatable design with full replications. The design matrix is shown in Table 3.

Experiments were carried out on an HMT (model: FN1U) milling machine. Surface finish was measured using a stylus type Perthometer (Mahr make). The cutting speed, feed and depth of cut were set in the semi finish milling range for the tool-work combinations. The cutting parameters such as cutting speed, feed rate and depth of cut were kept constant at 45 m/min, 0.14 mm/tooth and 0.4 mm respectively [17]. In order to achieve the desired objective, the investigations were planned in the following sequence: 1. Identifying the predominant factors which are having influence on surface roughness and finding the upper and lower limits of the chosen factors. 2. Developing the experimental design matrix. 3. Conducting the experiments as per the design matrix and recording the responses. 4. Developing the mathematical model, calculating the coefficients of the model and testing the significance of the coefficients.
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

5. Checking the adequacy of the developed model by ANOVA method and 6. Validating the mathematical model by experimentation.

2.1 Identifying the predominant factors which are having influence on surface roughness and finding the upper and lower limits of the chosen factors
Surface roughness of the work piece is an important attribute of quality in any machining operation. During machining many factors affects the surface finish. Based on the previous research work [11], it was found that in addition to the machining parameters such as cutting speed, feed rate and depth of cut the fluid application parameters also influence the quality of the surface generated. Apart from machining parameters, the independently controllable predominant fluid application parameters that influence the surface finish of the work piece were identified as: 1. pressure at the fluid injector (P) 2. Frequency of pulsing (F) 3. Quantity of application of cutting fluid. Preliminary experiments were carried out to fix the lower and upper limits of these factors. Accordingly, pressure at the fluid injector was fixed between 50 and 100 bar. In line with this factor, the frequency of pulsing was fixed between 250 and 750 pulses /min and the rate of application of cutting fluid was fixed between 2 and 10 ml/min. The upper limit of the factor was coded as +1.682 and the lower limit as -1.682. The coded values for intermediate values were calculated from the following relationship:

Where variable from

is the required coded value of a variable X; and X is any value of the to . The selected process parameters with their limits, units and

notations are given in Table 2.

Table 2 Process control parameters and their limits
Limits

Process parameters Pressure at fluid injector Frequency of pulsing Quantity of cutting fluid application

Units bar Pulses/min ml/min

Notations -1.682 P 50 F 250 Q 17 2

-1 60 350 3.5

0 75 500 6

1 90 650 8.5

1.682 100 750 10

International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

2.2 Developing the experimental design matrix

A five level, three-factors, central composite rotatable factorial design [18], consisting of 20 sets of coded conditions is shown in Table. 3. The design matrix comprises a full factorial design 2 [=8] plus six star points and six center points. All fluid application parameters at the intermediate level (0) constitute center points and combinations at either its lowest (-1.682) or highest (+1.682) level with the other two parameters at the intermediate level constituting the star points. Thus the 20

experimental runs allowed the estimation of the linear, quadratic and two-way interactive effects of the process parameters on the surface roughness. Table 3 Design matrix and observed values of surface roughness
S. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Design Matrix P F -1 -1 1 -1 -1 1 1 1 -1 -1 1 -1 -1 1 1 1 -1.682 0 1.682 0 0 -1.682 0 1.682 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Ra in microns Q -1 0.675 -1 0.591 -1 0.880 -1 0.627 1 0.817 1 0.514 1 0.870 1 0.564 0 0.840 0 0.400 0 0.615 0 0.711 -1.682 0.851 1.682 0.820 0 0.527 0 0.545 0 0.516 0 0.521 0 0.532 0 0.536

2.3 Conducting the experiments as per the design matrix and recording the responses
The experiments were conducted as per the design matrix at random, to avoid the possibility of systematic errors. The average roughness (Ra) is mostly used in industries, is taken as the response for this study. The surface roughness was measured using a stylus type Perthometer (Mahr make). Table 3 presents a record of the surface finish for each experiment. In this table, for experimental runs 15 to 20, even though the experimental setup and all machining conditions remain the same, the responses varied slightly. This is
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

due to the effect of unknown and unpredictable variables called noise factors, which crept into the experiments. To account for the impact of these unknown factors of the response, replicated runs were included in the design matrix.

2.4 Developing the mathematical model, Calculating the coefficients and testing the coefficients
The response function representing surface roughness can be expressed as Ra = f (P, F, Q) and the relationship selected being a second-order response surface. The function is as follows [19] Ra = b + b P + b F + b Q + b P + b F + b Q + b PF + b PQ + b FQ Where coefficients b1, b2 and b3 are linear terms, coefficients b, b and b are secondorder terms, and coefficients b, b and b are interaction terms. MINITAB software (version 13.1) software package was used to calculate these coefficients and the results obtained are shown in Table 4.
Table 4 Estimated values of regression coefficients S. Term Regression Standard pNo coefficient error value 1 Constant 0.530 0.011 0.000 2 P -0.123 0.007 0.000 3 F 0.037 0.007 0.001 4 Q -0.004 0.007 0.046 5 P*P 0.027 0.007 0.004 6 F*F 0.042 0.007 0.000 7 Q*Q 0.103 0.007 0.000 8 F*P -0.022 0.010 0.049 9 Q*P -0.034 0.010 0.005 10 Q*F -0.017 0.010 0.103

The regression model developed for predicting surface finish (Ra) is shown by the following equation (1). Surface finish Ra = 0.530 - 0.123 P + 0.037 F - 0.004 Q + 0.027 P + 0.042F + 0.103 Q - 0.022 PF - 0.034 PQ - 0.017 FQ. .(1)

2.5

Checking the adequacy of the developed model by ANOVA technique.

The model was examined for lack of fit, adequacy and efficiency. Table 5

presents the ANOVA summary of the model developed. The model is highly significant as indicated by the p-value (p<0.001). The goodness of the fit of the model was checked by the coefficient of determination (R). The value of R is always between 0 and 1. The
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

closer the R value to 1, the stronger will be the model and better will be its predictions [19, 20]. In this case, the value of the coefficient of determination (R = 0.982) indicates that 98.2% of the variability in the response could be explained by the model. In addition to this, the value of the adjusted coefficient of determination (Adj. R = 0.967) is also very high to advocate for a higher significance of the model.
Source of variation Regression Residual Sum of squares 0.413 0.007 Table 5 ANOVA summary for the model Degrees of Mean F-ratio pfreedom squares value 9 0.046 62.198 0.000 10 0.001 R 0.982

A p-value less than 0.05 indicated the significant model terms. The regression analysis of the experimental design presented in Table. 5 demonstrated that the linear model terms (P, F and Q), quadratic model terms (P, F, and Q) and interactive model terms (F*P, Q*P) are significant (p<0.05) and the interactive model term Q*F is insignificant (p>0.05). After dropping out the non-significant terms from Table. 4, the model can be expresses by the equation (2): Surface roughness Ra = 0.530 - 0.123 P + 0.037 F - 0.004 Q + 0.027 P + 0.042F + 0.103 Q - 0.022 PF - 0.034 PQ. . (2)

Studentized residuals were calculated to check the adequacy of the model. Residual represents the difference between the observed value of a response and the value that is fitted under the hypothesized model. Any observation with a studentized residual value greater than 3 was considered as outlier. It is found that except experimental run no. 1 with a studentized residual of -6.819, other values were well within the acceptable range.

2.6

Validating the mathematical model

Validity of the developed models was tested by drawing scatter diagrams that

shows the observed and predicted values of surface roughness. Fig. 3 shows the representative scatter diagram. Test runs were conducted to determine the accuracy of the model conformity. A comparison was made between predicted and actual values. The results obtained show that the model is sufficiently accurate as indicated by the R value which is as high as 0.976.

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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

Figure 3 Scatter diagram for surface roughness (Ra)

3. RESULTS AND DISCUSSIONS

The mathematical model as in equation (2) can be used to predict the surface roughness (Ra) by substituting the values of the respective process parameters. The surface roughness calculated from the final model for each set of coded values of fluid application parameters are represented graphically in Figure 4, Figure 5, Figure 6 and Figure 7. These plots show the convincing trends between cause and effect. The direct and interaction effects are discussed below.

3.1 Direct Effect of pressure at the fluid injector on Surface roughness

Figure 4 represents the direct effect of pressure at the fluid injector (P) on surface roughness (Ra). From the Figure, it is clear that surface finish increases with increase in pressure at the fluid injector.

Figure 4 Direct effect of pressure at the fluid injector on surface roughness The pressure at the fluid injector should be kept at high level (100 bar) corresponding to an exit velocity of 50 m/s to achieve better surface finish. The exit velocity of the fluid particles from the nozzle is directly proportional to the pressure at the fluid injector whereas the size of fluid particle is inversely proportional to the
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pressure [21]. The cutting force is directly related to the chip friction on the rake face. Any attempt to reduce friction on the rake face can bring forth lower cutting force, lower energy consumption and better surface finish. Hence when the pressure at the injector is high, the fluid particles will have higher velocity and smaller size which help them to penetrate into the tool-chip interface [3] leading to better lubrication at the contact surfaces and hence better surface finish.

3.2 Direct Effect of frequency of pulsing on Surface roughness

Figure 5 represents the direct effect of frequency of pulsing (F) on surface roughness (Ra). From the Figure 5, it is clear that surface roughness first decreases with increase in frequency of pulsing and then it increases.

Figure 5 Direct effect of frequency of pulsing on surface roughness

It is observed that frequency of fluid application in the range of 400 to 500 pulses/min favored better surface finish. It is reported that the frictional forces between two sliding surfaces can be reduced considerably by rapidly fluctuating the width of the lubricant filled gap separating them [22]. When a pulsing jet is used, the width of the lubricant filled gap between the tool rake face and the chip fluctuates with a frequency equal to the frequency of pulsing of the fluid jet. The width will be maximum when the fluid slug falls at the gap and will be minimum when no particles fall on the gap during the pulsing cycle. This process continues as the fluid particles fall in the gap between the chip and the tool intermittently. When the frequency of pulsing is 750 pulses/min, the quantity of fluid delivered per pulse will be very less when compared to 500 pulses/min for any fixed rate of fluid application. Hence the fluctuation in the width of the liquid film between the tool and the chip is less appreciable. A minimum quantity of cutting fluid should be delivered per pulse to get
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

appreciable fluctuation in the width. This leads to presence of fresh fluid droplets in to the tool chip interface unlike in the case where a stagnant layer of cutting fluid present if a continuous jet was employed [23]. The presence of fresh fluid droplets facilitates better filling of the gap on the tool chip interface thereby providing better lubrication and enhanced cooling as the droplets evaporate. When the frequency of pulsing is very high, the individual particles will be small and may lack in kinetic energy to penetrate in to the tool chip interface. This leads to less fluid particles reaching the rake face and hence less efficient rake face lubrication. It is also to be noted that the pulsing nature of the fluid delivery vanishes when the frequency of pulsing is very high and the fluid delivery tends to resemble a continuous jet, devoid of all the aforesaid advantages claimed for a pulsing jet.

3.3 Direct Effect of quantity of cutting fluid

Figure 6 represents the direct effect of Quantity of cutting fluid (Q) on surface roughness (Ra). From the Figure, it is clear that surface roughness decreases with increase in the quantity of cutting fluid and then increases.

Figure 5 Direct effect of frequency of pulsing on surface roughness

It is observed that the quantity of cutting fluid about 6 ml/min favored better surface finish. According to the empirical relationship developed by Hiroyasu and

Kadota [21], the mean diameter D for a droplet size cutting fluid injection is given by D = K(P)-0.135 0.121V0.131 Where P is the mean pressure drop, is the density of the medium in which injection of fluid takes place, V is the quantity of fluid delivered per pulse and K is a
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

constant. With lower delivery rates, droplet size decreases. When the size of the droplets is small, they can easily enter into the tool-chip interface and provide better rake face lubrication but when the size is too small, the kinetic energy of the fluid particles will be very less and the particles need a minimum kinetic energy to reach the tool-chip interface. It appears that a rate of fluid application of 6 ml/min favors the best

penetration from the point of view of the individual size of the fluid droplets and the kinetic energy. If the rate of fluid application is greater than 6 ml/min, the fluid particles will have higher kinetic energy but their sizes may not be favorable for their easy penetration into the tool-chip interface. When the rate of fluid application is much less than 6 ml/min, the size of individual particles may favor their passage into the tool-chip interface but they may not have sufficient kinetic energy owing to their smaller size. When the rate of flow is about 6 ml/min, it appears that both the size and the kinetic energy favors easy penetration of fluid particles into the tool-chip interface thereby providing better rake face lubrication and hence better surface finish. It is also to be noted that the pulsing nature of the fluid delivery is affected when the quantity of cutting fluid increases.

3.4 Interaction Effect of pressure at the fluid injector and Frequency of pulsing on Surface roughness

Figure 6 Interaction effect of pressure at the fluid injector and frequency of pulsing on surface roughness

The response surface plot shown in Figure 6 shows the interaction effect of pressure at the fluid injector and frequency of pulsing on surface roughness while the quantity of cutting fluid was maintained at 6 ml/min. From the contour of the surface, it is noted that surface roughness (Ra) is maximum (1.0565 m) when pressure at the fluid
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

injector was at lower (-1.682) level and frequency of pulsing at higher level (+1.682), and the surface roughness (Ra) was minimum (0.4 m) when pressure at the fluid injector was at higher (+1.682) level and frequency of pulsing at intermediate level (0).

3.5 Interaction Effect of pressure at the fluid injector and quantity of cutting fluid on Surface roughness
The response surface plot shown in Figure 7 shows the interaction effect of pressure at the fluid injector and quantity of cutting fluid on Surface roughness while the frequency of pulsing was maintained at 500 pulses/min.

Figure 7 Interaction effect of pressure at the fluid injector and quantity of cutting fluid on surface roughness

From the contour surface, it is noted that surface roughness (Ra) is maximum (1.194 m) when pressure at the fluid injector was at lower (-1.682) level and quantity of cutting fluid at higher level (+1.682), and the surface roughness (Ra) was minimum (0.394 m) when pressure at the fluid injector was at higher (+1.682) level and frequency of pulsing at intermediate level (0) for a constant value of frequency of pulsing at 500 pulses/min. The optimal conditions obtained form the analysis in coded form are P = 1.682, F = 0.0003 and Q = 0.297. The real values are pressure at the fluid injector at 100 bar, Frequency of pulsing at 500 pulses/min and the quantity of cutting fluid at 5.2936 ml/min. The minimum surface roughness (Ra) that can be achieved when the pressure at the injector is kept at 100 bar, frequency of pulsing at 500 pulses/min and the rate of fluid application at 6.706 ml/min is 0.3904 m. Cutting experiments were conducted to

validate the prediction and from Table 6 it is evident that the value of surface finish as predicted by the model matched well with the experimental result. Table 6 presents the
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International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 2, Number 1, Jan - Feb (2011), IAEME

comparison of the optimum surface finish as predicted by the model with the experimental results.
Sl No. 1. Table 6 Comparison of the predicted surface finish with experimental value Frequency of Quantity of Ra in microns Pressure at the % pulsing cutting fluid Observed Predicted error injector (bar) (Pulses/min) (ml/min) 100 500 6.706 0.4100 0.3904 4.7

4 CONCLUSIONS
Mathematical model for surface roughness has been developed to correlate the important fluid application parameters in machining of hardened AISI4340 steel. The experimental plan used is of rotatable central composite design. The three important input variables considered for the present research study is pressure at the fluid injector, frequency of pulsing and quantity of cutting fluid application. The influences of the fluid application parameters on surface roughness have been analyzed based on the mathematical model developed. The study leads to the following conclusions. 1. The surface roughness decreases with the increase of pressure at the fluid injector. 2. The surface roughness decreases with increase in frequency of pulsing up to certain level (about 500 pulses/min) and then increases with the increase of frequency of pulsing. 3. The surface roughness decreases with increase in the quantity of cutting fluid up to certain level (about 6.7 quantity of cutting fluid. 4. It was found that the predictions of the RSM matched well with the experimental results. ml/min) and then increases with the increase in

Acknowledgement
The authors thank the authorities of the Centre for Research in Design and Manufacturing of the Karunya University for facilitating this project and M/s Taugetec India (P) Ltd. for supplying cutting tools at concessional rates.

References
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3. A. S Varadarajan, P.K. Philip, B. Ramamoorthy, Investigations on hard turning with minimal cutting fluid application(HTMF) and its comparison with dry and wet turning, International Journal of Machine tool and Manufacture (2001) 193 200. 4. A.S Varadarajan, P.K. Philip, B. Ramamoorthy, Neural Network Assisted

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composition and delivery variables on performance in hard turning using minimal fluid in pulsed jet form, Journal of the Institution of Engineers (India), vol 82, (2001)1219. 11. Anil Raj, K. Leo Dev Wins, Robinson Gnanadurai, A. S Varadarajan, Investigations on hard milling with minimal fluid application, International conference on frontiers in Design and Manufacturing, Karunya University, Coimbatore (2008) pp183-187. 12. T. Thepsonthi, M. Hamdi, K. Mitsui, Investigation into minimal-cutting fluid

application in high-speed milling of hardened steel using carbide mills, International Journal of Machine Tools and Manufacture, 49 (2009) 156 162.

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13. Jack Feng CX, Wang X, Development of empirical models for surface roughness prediction in finish turning, International Journal of advanced Manufacturing technology, 2002;20:348-356. 14. Sreejith PS, Krishnamoorthy R, Malhotra SK, Narayanasamy K, Evaluation of PCD tool performance during machining of carbon / phenolic ablative composites, Journal of Material Processing Technology, 2000; 104:53 58. 15. Sahin Yusuf, Riza Motorcu A, Surface roughness prediction model in machining of carbon steel by PVD coated cutting tools, American Journal of Applied Science, 2004; 1(1): 12-17. 16. Varadarajan, A.S, B. Ramamoorthy, P.K. Philip, Formulation of a Cutting fluid for Hard Turning with Minimal Fluid Application, 20 th AIMTDR conference at Birla institute of Technology Ranchi, India, (2002) pp89-95. 17. K. Leo Dev Wins, A.S Varadarajan, Optimization of operating parameters during surface milling of hardened AISI4340 steel with minimal pulsed jet fluid application, Journal of Manufacturing Technology Today, Vol.8, Issue 12, Dec 2009, p3-10. 18. Murugan, N., and Parmar, R. S., Effects of MIG process parameters on the surfacing of stainless steel, Journal of Materials Processing Technology, 1994, 41: 381398. 19. Cochran, W. G., and Cox, G. M, Experimental Designs, 2nd Edition, John Wiley & Sons, Inc, New York, 1957, 346 354. 20. Box G E P, Hunter W G & Hunter J S, Statistics for experiments, John Wiley & Sons, Inc, New York, 1978. 21. Hiroyasu, T Kadota, Fuel drop size distribution in diesel combustion chamber, SAE paper 740715, SAE Transactions, vol. 83 (1974) 715 721. 22. Uzi Landman, "FRUSTRATED" lubricant molecules offer new strategy for reducing friction in mechanical devices, Georgia Tech Research news,

http://gtresearchnews.gatech.edu/newsrelease/FRICTION.html, July 1998. 23. Alexender, R, A.S. Varadarajan , P.K. Philip, Hard Turning with Minimum Cutting Fluid A Viable green Alternative on the shop floor, Proceedings of the 18th All India Manufacturing Technology Design and Research Conference, Kharagpur, (1998) pp 183-187.
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