Mainak Ghosh

A Dissertation on
EXPERIMENTAL ANALYSIS OF
MACHINING PARAMETERS OF
HARD MATERIALS (Ti-alloys)
By
MAINAK GHOSH B120520870

ASLAM KHAN B120520860
ADITYA NARAYAN TIWARI B120520803
RANJEET RAKTADE B120520906
Guided By
Prof. B. D. NELGE
Mechanical Engineering Department

Indira College of Engineering & Management,
Pune - 410506
[2016-17]
I
Shree Chanakya Education Societys
Indira College of Engineering &

Management, Pune.
CERTIFICATE
This is to certify that
1. Mainak Ghosh (B120520870)
2. Aslam Khan (B120520860)
3. Aditya Narayan Tiwari (B120520803)
4. Ranjeet Raktade (B120520906)
have successfully completed the Dissertation entitled Experimental

Analysis of Machining parameters of Hard Materials (Ti-alloy)
under my supervision, in the partial fulfillment of Bachelor of
Engineering - Mechanical Engineering of Savitribai Phule Pune
University.
Prof. B.D.Nelge Prof. M. G. Bhong Dr. Sunil Admuthe

Guide Head, Mechanical Engineering Principal
Department
External Examiner
Place:
Date:
II
ACKNOWLEDGEMENT
With immense pleasure, we are presenting this project report as a part of the
curriculum of B.E. (Mechanical). We wish to thank all the people who gave us
endless support right from the stage the idea was conceived.
We are heartily thankful to Prof. Balaji D. Nelge whose encouragement,

guidance and support from the initial to the final level enabled us to develop an
understanding of the subject.
We would like to thank Prof. Mahesh G. Bhong (HOD, Mechanical

Department) & Dr. Sunil Admuthe (Principal) for giving us opportunity to work
on this interesting topic. This project would not be possible without help of our
internet department &library department who helped us gathering the information
from various sources.
Lastly, we offer our regards and blessings to all of those who supported us in
any respect during the completion of the project.
MAINAK GHOSH
ASLAM KHAN
ADITYA NARAYAN TIWARI
RANJEET RAKTADE
III
TABLE OF FIGURES
Figure 5-1 Isometric Cad Model ................................................................................. 16
Figure 5-2 Different Views ......................................................................................... 16
Figure 7-1 Working Principle of Vortex Tube ........................................................... 45
Figure 8-1 Micro-structure for Dry Machining (0.1Depth @120 Rpm)..................... 56
Figure 8-2 Micro-structure for Wet Machining (0.1Depth @120 Rpm) .................... 57
Figure 8-3 Micro-structure for VTJA Machining (0.1Depth @120 Rpm) ................. 58
IV
LIST OF PHOTOGRAPHS
Photo 3-1 Experimental Setup .................................................................................... 13
Photo 6-1 Titanium alloy bar ...................................................................................... 18
Photo 6-2 Effect of Machining on CBN insert ........................................................... 19
Photo 6-3 TRUMAC 6082 medium duty lathe ........................................................... 20
Photo 6-4 Infrared Thermometer ................................................................................ 21
Photo 6-5 Thermal Camera ( FLIR E30) .................................................................... 22
Photo 6-6 Rockwell hardness tester ............................................................................ 24
Photo 6-7 Surface roughness tester ............................................................................. 25
Photo 7-1 Experimental setup of Dry Machining ....................................................... 28
Photo 7-2 Experimental setup of wet machining ........................................................ 36
Photo 7-3 Experimental setup of VTJA machining .................................................... 48
V
LIST OF TABLES
Table 4-1 Periodic Table ................................................................................................... 6

Table 6-1 Cutting parameters .......................................................................................... 18
Table 7-1 List of Temperature Distribution Tables for Dry Machining (Grade 5) ......... 22
Table 7-2 List of Temperature Distribution Tables for Dry Machining (JIS Class 4) ..... 24
Table 7-3 List of Hardness Tables for Dry Machining (Grade 5).................................... 25
Table 7-4 List of Hardness Tables for Dry Machining (JIS Class 4) .............................. 25
Table 7-5 List of Temperature Distribution Tables for Wet Machining (Grade 5) ........ 31
Table 7-6 List of Temperature Distribution Tables for Wet Machining (JIS Class 4) ... 33
Table 7-7 List of Hardness Tables for Wet Machining (Grade 5) .................................. 34
Table 7-8 List of Hardness Tables for Wet Machining (JIS Class 4) ............................. 34
Table 7-9 List of Temperature Distribution Tables for VTJA Machining (Grade 5) ..... 42
Table 7-10 List of Temperature Distribution Tables for VTJA Machining (JIS Class 4) 43
Table 7-11 List of Hardness Tables for VTJA Machining (Grade 5 ) ............................. 44
Table 7-12 List of Hardness Tables forVTJA Machining (JIS Class 4 ) ......................... 44
VI
LIST OF GRAPHS
Graph 7-1 Surface Roughness Ti-alloy (Grade 5) (Dry) 80 rpm .............................. 26

Graph 7-2 Surface Roughness Ti-alloy (Grade 5) (Dry) 120 rpm ............................ 26
Graph 7-3 Surface Roughness Ti-alloy (JIS Class 4) (Dry) 80 rpm ......................... 27
Graph 7-4 Surface Roughness Ti-alloy (JIS Class 4) (Dry) 120 rpm ....................... 27
Graph 7-5 Surface Roughness Ti-alloy (Grade 5) (Wet) 80 rpm ............................. 35
Graph 7-6 Surface Roughness Ti-alloy (Grade 5) (Wet) 120 rpm ........................... 35
Graph 7-7 Surface Roughness Ti-alloy (JIS Class4) (Wet) 80 rpm ......................... 36
Graph 7-8 Surface Roughness Ti-alloy (JIS Class4) (Wet) 120 rpm ....................... 36
Graph 7-9 Surface Roughness Ti-alloy (grade 5) (VTJA) 80 rpm ........................... 45
Graph 7-10 Surface Roughness Ti-alloy (grade 5) (VTJA) 120 rpm ......................... 45
Graph 7-11 Surface Roughness Ti-alloy (JIS Class4) (VTJA) 80 rpm ...................... 46
Graph 7-12 Surface Roughness Ti-alloy (JIS Class4) (VTJA) 120 rpm .................... 46
Graph 8-1 Temperature of tool chip interface at fixed intervals of time .................. 47
Graph 8-2 Rockwell hardness as measured from one end ........................................ 48
VII
NOMENCLATURE
T- Temperature (C)
Velocity vector (m/s)
Angular velocity (rad/s)
r - Position vector (m)
Cp Specific heat at constant pressure (J/Kg.K)
HR - Rockwell Hardness Number
d Depth (from the zero load point)
N & s - Scale factors that depend on the scale of the test being conducted
Ra - Roughness Average (microns.)
Rq - Root Mean Square (RMS) roughness (microns.)
Rz Average maximum height of profile (microns.)
VIII
TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................. 1
1.1 Objectives to be accomplished ........................................................................ 2
1.2 Parameters to be covered................................................................................. 2
2 LITERATURE REVIEW ....................................................................................... 3
3 EXPERIMENTAL INVESTIGATION .................................................................. 5
4 MATERIAL SELECTION ..................................................................................... 6
Titanium alloy ............................................................................................................ 6
4.1 Categories ........................................................................................................ 7
4.2 Properties ......................................................................................................... 7
4.3 Grades.............................................................................................................. 8
5 DESIGN OF EXPERIMENTAL SETUP (CAD MODEL) ................................... 9
6 EXPERIMENTAL PROCESS ............................................................................. 10
6.1 Resources required in our project.................................................................. 10
6.1.1 Work piece Material .............................................................................. 10
6.1.2 Cutting Tool (Cubic Boron Nitride Tip Tool & Carbide Cutting Tool) ....... 11
6.1.3 Selection of Lathe .................................................................................. 12
6.1.4 Infrared Thermometer ............................................................................ 13
6.1.5 Thermal Camera (FLIR E30) ................................................................. 14
6.1.6 Vortex Tube Jet Assisted (VJTA) .......................................................... 15
6.1.7 Rockwell hardness tester........................................................................ 16
6.1.8 Surface roughness tester (MITUTOYO SURFTEST- 210 SJ) .............. 17
6.2 Experimental Workflow ................................................................................ 18
7 MACHINING ....................................................................................................... 20
7.1 DRY MACHINING ...................................................................................... 20
7.1.1 Temperature Distribution ....................................................................... 21
7.1.2 Surface Hardness (HRC) (Rockwell Hardness C scale) ..................... 25
7.1.3 Surface Roughness ................................................................................. 26
7.2 WET MACHINING ...................................................................................... 28
7.3 VTJA (VORTEX TUBE JET ASSISTED MACHINING) .......................... 38
IX
8 RESULTS ............................................................................................................. 47
8.1 Temperature distribution ........................................................................... 47
8.2 Surface Hardness ....................................................................................... 48
8.3 Micro Structural Investigation ................................................................... 49
9 CONCLUSION .................................................................................................... 52
10 BIBLIOGRAPHY ............................................................................................. 54
X
ABSTRACT
Titanium alloys are widely used in aerospace, chemical, marine and automotive
industries, especially high- end automobiles due to their excellent strength-to-weight
ratio, corrosion resistance, and ability to retain strength at high temperature. However,
these alloys are classified as a difficult-to-cut due to their poor thermal conductivity,
reactivity with tool material, high strength and low modulus of elasticity. Besides
various measures to improve machinability of titanium alloys, the key areas of
research pertaining to their machining are-cutting tool material and geometry
development, use of lubricant application, use of varying machining environments to
improve machinability and so on.
This article focuses on machinabilty of titanium alloys under

various machining environments such as Dry, Wet and VTJA conditions. The main
objectives of this dissertation is to understand the effect of change in machining
environment on various aspects of machining of titanium alloys viz., Thermal
distribution, Surface hardness and surface roughness. On the other hand, the elevated
temperature environment reduces the cutting forces and thereby increases the material
removal rate along and surface quality. Based on the study, recommendations to
improve the machinability of titanium alloys have been evolved.
XI
Experimental analysis of machining parameters of hard materials (Ti-alloy)
1 INTRODUCTION
The fact that titanium sometimes is classified as difficult to machine by traditional
methods in part can be explained by the physical, chemical, and mechanical properties
of the metal.
Titanium is a poor conductor of heat. Heat, generated by the cutting action,

does not dissipate quickly. Therefore, most of the heat is concentrated on the cutting
edge and the tool face.
Titanium has a strong alloying tendency or chemical reactivity with materials
in the cutting tools at tool operating temperatures. This causes galling, welding, and
smearing along with rapid destruction of the cutting tool.
Titanium has a relatively low modulus of elasticity, thereby having more
"springiness" than steel. Work has a tendency to move away from the cutting tool
unless heavy cuts are maintained or proper backup is employed. Slender parts tend to
deflect under tool pressures, causing chatter, tool rubbing, and tolerance problems.
Rigidity of the entire system is consequently very important, as is the use of sharp,
properly shaped cutting tools.
Titanium's fatigue properties are strongly influenced by a tendency to surface
damage if certain machining techniques are used. Care must be exercised to avoid the
loss of surface integrity, especially during grinding.
Titanium's work-hardening characteristics are such that titanium alloys
demonstrate a complete absence of "built-up edge." Because of the lack of a
stationary mass of metal (built-up edge) ahead of the cutting tool, a high shearing
angle is formed. This causes a thin chip to contact a relatively small area on the
cutting tool face and results in high bearing loads per unit area. The high bearing
force, combined with the friction developed by the chip as it rushes over the bearing
area, results in a great increase in heat on a very localized portion of the cutting tool.
Furthermore, the combination of high bearing forces and heat produces cratering
action close to the cutting edge, resulting in rapid tool breakdown.
ICEM, BE (Mechanical Engineering) 2016-17

1
1.1 Objectives to be accomplished
1. Metallographic study of difficult to machine materials.

2. Study of machining phenomena and various cutting process parameters like speed,
feed, depth of cut, for turning of difficult to machine materials.
3. To develop correlations among the temperature, surface finish & surface hardness.
4. Experimentation for machining output for difficult to machine materials.
5. Applying Design of experiments to the proposed study.
1.2 Parameters to be covered
1. Machining various Ti alloy grades of Difficult to machine materials.

2. Use of cubic boron nitride (CBN) single point cutting tools/Carbide cutting
tools.
3. The machining process involved will be machining operation involving
various cutting ,Speeds, feed, depth of cut, machining conditions.
4. Assisted Cold air jet & cutting oil as coolant be supplied at varying
temperatures.
5. Machining with different cooling Techniques like Dry, Wet, VTJA.
6. Study of variations in Thermal distribution, Surface hardness & surface
roughness parameters post machining etc.
7. Study of the effect of machining on Micro-structure of Ti-Alloy for different
machining conditions.

2
2 LITERATURE REVIEW
On going through the research work conducted by ( Balaji Nelge, Kiran

Devade, A.T. Pise, V.M. Kale),which involve machining without the use of any
cutting fluid is known as dry or green machining. It is becoming increasingly more
popular due to concern regarding the safety of environment. Most industries apply
cutting fluids/coolants when their use is not necessary. The coolants and lubricants
used for machining represents 1620% of the manufacturing costs, hence the
unnecessary use of these fluids should be restricted. Moreover there are certain
materials that are considered as difficult to machine, for machining of such materials
dry machining is advisable. An attempt is made here to carry out study with dry, wet
as well as dry machining using cold air stream coming out of vortex tube, and the
work piece is analyzed thermally as well as metallographically.
The results are promising and have shown better results for cold air machining
using vortex tube. The machining is performed using two grades of materials namely
H13A, and AISI1050 with coated carbide tools. The tests are conducted with coolant,
without coolant and with cold air stream as coolant, After the tests the thermal plots
and metallographic study for hardness and surface finish have revealed that using cold
air as coolant produces better surface finish while maintaining the tool tip and work
surface at significantly lower temperatures.The same is being termed here as Vortex
Tube Jet Assisted (VTJA) machining. [1]
C. Veiga, J. P. Davim and A.J.R. Loureiro) worked on Titanium
alloys.That are widely used in the engineering field, namely in the aerospace,
automotive and biomedical parts, because of their high specific strength and
exceptional corrosion resistance. [2] However, the machinability of titanium alloys is
difficult due to their low thermal conductivity and elastic modulus, high hardness at
elevated temperature, and high chemical reactivity. This article reviews the state of
the art of machinability of titanium alloys by using CBN inserts, and focuses on the
analysis of the process details, namely the especial techniques for cutting
improvement, machining forces, chip formation and cutting temperature. The
influence of titanium properties on the machinability is also highlighted. Particular
attention is given to the turning process of Ti-6Al-4V alloy.
The research work (Mitsuo Niinomi) on titanium explain as Nb, Ta and Zr are
the favorable non-toxic alloying elements for titanium alloys for biomedical

3
applications. Low rigidity titanium alloys composed of non-toxic elements are getting
much attention. The advantage of low rigidity titanium alloy for the healing of bone
fracture and the remodelling of bone is successfully proved by fracture model made in
tibia of rabbit. Ni-free super elastic and shape memory titanium alloys for biomedical
applications are energetically developed. Titanium alloys for not only implants, but
also dental products like crowns, dentures, etc. are also getting much attention in
dentistry Bioactive surface modifications of titanium alloys for biomedical
applications are very important for achieving further developed biocompatibility. [3]
Narutaki, Murakoshi, Takeyama performed turning tests on alloys Ti-6Al-
4V & Ti-5Al-2.5Sn with cutting speeds 0.5 to 5.0 m/s, depth of cut 0.5 mm, feed 0.1
mm/rev and cutting fluid of soluble type and found that for both the work pieces,CBN
tool exhibited an excellent cutting performance compared to other tools like straight
tungsten carbide (WC-K10),cemented TiN, pure aluminium oxide type of
ceramic,coated TiC and sintered diamond. Cutting force for Ti-alloy was claimed to
be about one half of that of a carbon steel (0.45%C) and cutting temperature to be
about 2500C higher than that of carbon steel because of low thermal conductivity and
low density of Ti-alloys.
Bharatkumar M. Sutaria & Dhananjay V. Bhatt carried out work on

Titanium alloy (Ti-6Al-4V) Grade 5. Which is most popular alloy widely used in
Aerospace, Automobile and Biomedical part manufacturing due to its inherent
properties like high strength to weight ratio is minimum at elevated temperature,
dimensional stability, great corrosion resistant etc. but on other hand Ti-6Al-4V
shows machining challenges on base performance criteria like metallurgical aspect,
chip formation, cutting tool wear, lubrication strategy and surface integrity. In this
paper study of various machining problem discussed by different researchers and their
probable solution, which helps to reduce tool wear, high surface finish with effective
lubrication strategy by reducing machining complexity. [4]

4
3 EXPERIMENTAL INVESTIGATION
The machining of hard material (Titanium Alloy) is generally carried by Non

Conventional Machining Methods like EDM, WEDM, ECM, LBM etc which
increases the cost and duration of machining these Hard materials. Thus the use of
Conventional Machining Methods for machining hard material (Titanium Alloy) is
essential. We consider machining of Titanium Alloy by Geared Lathe Machine and by
use of Cubic Boron Nitrate (CBN) / Carbide cutting tool under variable condition of
cutting fluids which include Dry, Wet & VTJA condition. The parameters like surface
hardness, surface finish and Thermal distribution during machining are studied during
machining under variable conditions. The aim is to determine optimum cutting
parameters which reduces tool wear and improves machinability, reduces specific
power consumption, enhance thermal distribution etc under Dry, Wet & VJTA
conditions. [5]
Photo 3-1 Experimental Setup

5
4 MATERIAL SELECTION
Titanium is lustrous transition metal with a silver color, low density and high
strength. It is highly resistant to corrosion in sea water, aqua regia and chlorine. The
two most useful properties of the metal are corrosion resistance and the highest
strength-to-weight ratio of any metal
Table 4-1 Periodic Table
Titanium alloy
Titanium alloys are metals that contain a mixture of titanium and other chemical
elements. Such alloys have very high tensile strength and toughness (even at extreme
temperatures). They are light in weight, have extraordinary corrosion resistance and
the ability to withstand extreme temperatures. However, the high cost of both raw
materials and processing limit their use to military applications, aircraft, spacecraft,
medical devices, highly stressed components such as connecting rods on expensive
sports cars and some premium sports equipment and consumer electronics.
Although commercially pure titanium has acceptable mechanical properties

and has been used for orthopaedic and dental implants, for most applications titanium
is alloyed with small amounts of aluminium and vanadium, typically 6% and 4%
respectively, by weight. [5]

6
4.1 Categories
Titanium alloys are generally classified into four main categories:-
Alpha alloys which contain neutral alloying elements (such as tin) or alpha
stabilisers (such as aluminium or oxygen) only.
Examples:- Ti-5AL-2SN-ELI, Ti-8AL-1MO-1V.
Near-alpha alloys contain small amount of ductile beta-phase.
Examples:- Ti-6Al-2Sn-4Zr-2Mo, Ti-5Al-5Sn-2Zr-2Mo, IMI 685, Ti 1100.
Alpha and beta alloys, which are metastable and generally include some
combination of both alpha and beta stabilisers.
Examples:- Ti-6Al-4V, Ti-6Al-4V-ELI, Ti-6Al-6V-2Sn.
Beta and near beta alloys, which are metastable and which contain sufficient
beta stabilisers (such as molybdenum, silicon and vanadium) to allow them to
maintain the beta phase when quenched, and which can also be solution treated and
aged to improve strength.
Examples:- Ti-10V-2Fe-3Al, Ti-13V-11Cr-3Al, Ti-8Mo-8V-2Fe-3Al
4.2 Properties
Generally, beta-phase titanium is the more ductile phase and alpha-phase is

stronger yet less ductile, due to the larger number of slip planes in the bcc structure of
the beta-phase in comparison to the hcp alpha-phase. Alpha beta- phase titanium has a
mechanical property which is in between both.
Titanium dioxide dissolves in the metal at high temperatures, and its formation is very
energetic. These two factors mean that all titanium except the most carefully purified
has a significant amount of dissolved oxygen, and so may be considered a TiO alloy.
Oxide precipitates offer some strength (as discussed above), but are not very
responsive to heat treatment and can substantially decrease the alloys toughness.
Many alloys also contain titanium as a minor additive, but since alloys are usually
categorized according to which element forms the majority of the material, these are
not
usually considered to be titanium alloys as such. See the sub-article on titanium
applications. Titanium alone is a strong, light metal. It is stronger than common, low-
carbon steels, but 45% lighter. It is also twice as strong as weak aluminium alloys but

7
only 60% heavier. Titanium has outstanding corrosion resistance to sea water, and
thus is used in propeller shafts, rigging and other parts of boats that are exposed to sea
water. Titanium and its alloys are used in airplanes, missiles and rockets where
strength, low weight and resistance to high temperatures are important. Further, since
titanium does not react within the human body, it and its alloys are used to create
artificial hips, pins for setting bones, and for other biological implants.
4.3 Grades
The grades which are commercially used are,
Grade 1, is the most ductile and softest titanium alloy. It is a good solution for
cold forming and corrosive environments. ASTM/ ASME SB-265 provides the
standards for commercially pure titanium sheet and plate.
Grade 2, unalloyed titanium, standard oxygen.
Grade 2H, Unalloyed titanium (Grade 2 with 58 ksi minimum UTS).
Grade 3, Unalloyed titanium, medium oxygen
Grades 1-3 are unalloyed and considered commercially pure or CP.
Generally the tensile and yield strength goes up with grade number for these pure
grades. The difference in their physical properties is primarily due to the quantity of
interstitial elements. They are used for corrosion resistance applications where cost,
ease of fabrication, and welding are important.
Grade 5, also known as Ti6Al4V, Ti-6Al-4V or Ti 6-4, is the most commonly
used alloy. It has a chemical composition of 6% aluminium, 4% vanadium, 0.25%
(maximum) iron, 0.2% (maximum) oxygen, and the remainder titanium.[6] It is
significantly stronger than commercially pure titanium while having the same
stiffness and thermal properties (excluding thermal conductivity, which is about 60%
lower in Grade 5 Ti than in CP Ti).[7] Among its many advantages, it is heat
treatable. This grade is an excellent combination of strength, corrosion resistance,
weld and fabric ability.
Grade 6 contains 5% aluminium and 2.5% tin. It is also known as Ti-5Al-
2.5Sn. This alloy is used in airframes and jet engines due to its good weldability,
stability and strength at elevated temperatures.

8
5 DESIGN OF EXPERIMENTAL SETUP (CAD MODEL)
Figure 5-1 Isometric Cad Model
Figure 5-2 Different Views

9
6 EXPERIMENTAL PROCESS
6.1 Resources required in our project
6.1.1 Work piece Material

The investigation is carried on Hard Material (Titanium Alloy) of initial
diameter 25mm and length 100 mm is used in plain turning.
Titanium alloy offer High strength, Light weight ,Formability ,Excellent
Corrosion Resistance etc which have lead it to various applications.
Titanium Alloy is one of the expensive alloy and further Non-conventional
Machining increses its cost of production, hence search for optimum parameters of
Conventional Machining Methods is utmost is important.
The titanium alloy used during the experimental analysis is of Grade 5 tested
by chemical testing.
Mechanical And physical properties of the respective alloy were studied. [6]
Photo 6-1 Titanium alloy bar

10
6.1.2 Cutting Tool (Cubic Boron Nitride Tip Tool & Carbide Cutting Tool)
The machining of titanium alloy requires cutting insert which have capability
to cut material with hardness upto 36 HRC as the hardness of titanium alloy is about
36 HRC.
Hence we consider use of Cobalt Boron Nitrate (CBN) cutting insert as it have
capability to cut material upto 45 HRC.
As we were taking trial run for proper working of instruments on our CBN
insert which we had planned to use initially, was not giving satisfactory service and
had a short tool life, owing to the fact that CBN (Cubic Boron Nitride) itself is very
hard, and as it is trying to cut a harder material, flank wear was occurring because of
which the tool life was very less.
So we changed our insert and opted for a 3 sided Carbide insert instead. As it is
having satisfactory performance coupled with a high tool life, we selected this for our
entire project work.
The close up photographs as shown below make the above said matter even more
clear.
We are able to see that CBN is virtually worn out after just some passes, but the
Carbide insert on the other hand is not showing any apparent signs of tool wear.
Photograph of a new 2-sided CBN insert

Worn out edges after turning
(Before) (after)
Photo 6-2 Effect of Machining on CBN insert

11
6.1.3 Selection of Lathe
There are 2 types of lathes available in our workshop-
1) Belt driven Lathe
2) All gear driven lathe
We opted for the Gear driven Lathe as it is much more sturdy and robust, than the belt
driven one. It is also capable of producing higher speeds (~ 900 RPM),than the belt
driven lathe.
This lathe has automatic feed which is required for carrying out our project work, the
photograph of the lathe is included below.
Photo 6-3 TRUMAC 6082 medium duty lathe

12
6.1.4 Infrared Thermometer
Photo 6-4 Infrared Thermometer
The analysis of Thermal distribution during machining of titanium alloy bar by

CBN cutting tool is done by Infrared Thermometer. Infrared thermometers measure
the surface temperature of an opaque object. The Thermometers optics sense infrared
energy, which is collected and focused onto a detector.The Thermometers electronics
then translate the information into a displayed temperature reading which appears on
the display. The laser is used for aiming purposes only. The Thermometer turns on
when you press the trigger. The Thermometer turns off when no activity is detected
for 7 seconds .To measure temperature, aim the Thermometer at the target, pull and
hold the trigger. Release the trigger to hold a temperature reading. Be sure to consider
distance-to-spot size ratio and field of view. [7]
Figure 6-1 Temperature measurement using Infrared Thermometer

13
6.1.5 Thermal Camera (FLIR E30)
Photo 6-5 Thermal Camera ( FLIR E30)
Infrared energy is just one part of the electromagnetic spectrum, which

encompasses radiation from gamma rays, x-rays, ultra violet, a thin region of visible
light, infrared, terahertz waves, microwaves, and radio waves. These are all related
and differentiated in the length of their wave (wavelength). All objects emit a certain
amount of black body radiation as a function of their temperatures.
Generally speaking, the higher an object's temperature, the more infrared radiation is
emitted as black-body radiation. A special camera can detect this radiation in a way
similar to the way an ordinary camera detects visible light. It works even in total
darkness because ambient light level does not matter. This makes it useful for rescue
operations in smoke-filled buildings and underground.
A major difference with optical cameras is that the focusing lenses cannot be made of
glass, as glass blocks long-wave infrared light. Special materials such
as Germanium or Sapphire crystals must be used. Germanium lenses are also quite
fragile, so often have a hard coating to protect against accidental contact. The higher
cost of these special lenses is one reason why thermographic cameras are more
costly.Sometimes these monochromatic images are displayed in pseudo-color, where
changes in color are used rather than changes in intensity to display changes in the
signal. This technique, called density slicing, is useful because although humans have
much greater dynamic range in intensity detection than color overall, the ability to see
fine intensity differences in bright areas is fairly limited.For use in temperature
measurement the brightest (warmest) parts of the image are customarily colored
white, intermediate temperatures reds and yellows, and the dimmest (coolest) parts
black. A scale should be shown next to a false color image to relate colors to
temperatures.

14
6.1.6 Vortex Tube Jet Assisted (VJTA)
Vortex tube jet assisted machining utilizes high pressure air initially which is
introduced at tool work piece interface through vortex tube. Vortex tube is a device
capable of converting the high pressure jet of air into two streams viz. cold and hot
stream based on the heat transfer principles. The hot stream of air escaping out of the
vortex tube is allowed to escape into the atmosphere and the cold stream jet is
directed to interface. Using vortex tube it is possible to produce cold air at near zero
and below zero degrees. The air stream comes out at sufficient velocity and thus it
helps to clean the swarf accumulated at the interface. This is a clean and cost effective
solution to machining problems associated with dry machining of difficult to machine
metals. From the discussion above it is clear that though number of different methods
are suggested the cost effectiveness parameter of all the above methods is majorly
governed by the rate of production and the volume of production required in the
facility. If cryogenic machining is considered it adds to the cost of getting and
utilizing the cryogenic fluids it needs changes to be made in the manufacturing setup.
Minimum quantity lubrication (MQL) has to be ascertained from case to case basis.
Using self lubricated tools is one of the options but needs specially ordered and
manufactured tools. But VTJA being dependent on compressed air and compressed
air can be made available easily in a manufacturing unit it is definitely a cost effective
method. The vortex tube is a light and silent in operation it can be easily used without
disturbing the manufacturing setup. [9]
Figure 6-2 Vortex Jet Tube

15
6.1.7 Rockwell hardness tester
Photo 6-6 Rockwell hardness tester
The Rockwell scale is a hardness scale based on indentation hardness of a

material. The Rockwell test determines the hardness by measuring the depth of
penetration of an indenter under a large load compared to the penetration made by a
preload. There are different scales, denoted by a single letter, that use different loads
or indenters. The result is a dimensionless number noted as HRA, HRB, HRC, etc.,
where the last letter is the respective Rockwell scale.
When testing metals, indentation hardness correlates linearly with tensile
strength. This important relation permits economically important non destructive
testing of bulk metal deliveries with lightweight, even portable equipment, such as
hand-held Rockwell hardness testers.
The equation for Rockwell Hardness is

HR = N -

, where d is the depth (from the zero load point), and N and s are scale factors that
depend on the scale of the test being used. [5]

16
6.1.8 Surface roughness tester (MITUTOYO SURFTEST- 210 SJ)
Photo 6-7 Surface roughness tester
The most common method is to use a diamond stylus profilometer. The stylus is run
perpendicular to the lay of the surface.[1] The probe usually traces along a straight line
on a flat surface or in a circular arc around a cylindrical surface.
The length of the path that it traces is called the measurement length. The wavelength
of the lowest frequency filter that will be used to analyze the data is usually defined as
the sampling length. Most standards recommend that the measurement length should
be at least seven times longer than the sampling length, and according to the Nyquist
Shannon sampling theorem it should be at least two times longer than the wavelength
of interesting features. The assessment length or evaluation length is the length of
data that will be used for analysis. Commonly one sampling length is discarded from
each end of the measurement length. 3D measurements can be made with a
profilometer by scanning over a 2D area on the surface.
Setting attachment : V type , for measuring in the cylinder axis direction
The V-width is adjustable to the cylinder diameter facilitating axial measurement of a
wide range of cylinder diameters. [9]
Adjustable range:
Dia - 5 ~ 150mm

17
6.2 Experimental Workflow
So what our project is offering is an attempt to optimize the machining parameters

for economical machining (viz. Turning of Titanium alloy)!!
We are planning to conduct the machining of the Ti-alloy under different parameters
such as spindle speed (RPM), Depth of cut, Feed and lastly the cooling conditions
employed.
Speed (RPM) Depth of cut (mm)
0.1
80
0.15
0.2
0.1
120
0.15
0.2
Table 6-1 Cutting parameters
We are going to study the effect of machining by comparing the parameters given
below :
a) Temperature distribution along the lengthwise direction (will be denoted by x)

b) Surface roughness of the bar. (will be denoted by y)
c) Surface hardness of the bar. (will be denoted by z)
The effect of Machining on the micro-Structure of the Ti- Alloys will also considered
by going for microstructural examination of the specimens, during the course of
project.

18
Our experimental study will be conducted in the following manner -
Case-1 Dry Turning of titanium bar (i.e. Without application of the coolant)-
Here we are going to employ 5 levels of spindle speed (RPM) and 5 levels of depth of
cut
We will be keeping the feed as automatic in this case and then we are ready for
checking the x, y and z parameters respectively.
Here we are not employing any artificial cooling and the tool and work piece cooling
takes place by natural convection.
Case-2 Wet Turning of titanium bar (i.e. Coolant is utilised)
We will be keeping the feed as automatic in this case and then we are ready for
Here we are employing artificial cooling (synthetic coolant) and the tool and
workpiece cooling takes place by forced convection. as the heat generated during
turning is carried away by the coolant.
Case-3 Turning of titanium bar by employing artificial cooling (i.e VTJA tube is
used)-
Here we are going to employ 5 levels of spindle speed (RPM) and 5 levels of depth of
cut We will be keeping the feed as automatic in this case and then we are ready for
Here we are employing artificial cooling (VTJA tube) and the tool and work piece
cooling takes place by forced convection. as the heat generated during turning is
carried away by the cool air passing from the VTJA tube. This device requires the
usage of an air compressor for effective operation. Lastly we are going to plot the
results obtained under different cases in graphical format and will suggest the
optimum cutting combination for safe and economical turning of the Titanium alloy.

19
7 MACHINING
7.1 DRY MACHINING
Dry machining is considered a more sustainable process than machining with

cutting fluid due to the absence of lubricants and coolants, which results in a reduced
use of resources. In dry turning of titanium/super alloy, the cutting forces required are
lower than those required using cutting fluids , and a better surface quality is achieved
than in wet machining.
There are many advantages of dry machining, such as increased flexibility, decreased
cycle times, reductions in machine tool costs, and elimination of environmentally
hazardous cutting fluids. To improve the fatigue strength, corrosion resistance of the
product surface roughness is desired.
To enrich certain surface roughness in dry machining tools with carbide coated is
necessary, also different types of coated tool is essential for cutting parameter. This
type of tools influence the high temperature, high resistivity and also less tool wear.
While turning operation in lathe or CNC machine hard coating deposits are necessary,
it can be either done by PVD(Physical vapor deposition) and CVD(chemical vapour
deposition).also some coating of PVD can be used at sharp edges and complex edges.
Also this carbide coating tools play an vital role in tool life and machining
performance.
Photo 7-1 Experimental setup of Dry Machining

20
Type of turning insert being used Coated Carbide 3 sided insert
Type of Lathe Machine All geared TRUMAC 6082 medium duty lathe
Temperature sensing device - FLIR E30 Infrared Camera
Procedure
In our project, first we have procured titanium alloy bars of 25 mm 205 mm and
we have turned them in such a manner that the same bar is used for 2 different studies
by turning upto 100 mm on both sides and selecting the appropriated depth of cut for
each piece.
Then we have measured the temperature at the tool chip interface by using the FLIR
IR camera at premeditated intervals of time say (15 sec).
The readings have been given for all the sets.The tests which were subsequently
carried out are Surface roughness and surface hardness.
The results are presented in tabular as well as graphical form for convenience of the
reader.
Dry Machining
7.1.1 Temperature Distribution
a) Ti-Alloy ( Grade 5 )
Speed (80 rpm) Speed (120 rpm)

Depth of Cut (0.1 mm) Depth of Cut (0.1mm)
Sr No. Tmax C Time Interval(s) Sr No. Tmax C Time Interval(s)
1 113 15 1 121 15
2 123 15 2 143 15
3 164 15
3 105 15
4 178 15
4 114 15 5 188 15
5 116 15 6 196 15
6 128 15 7 202 15
7 142 15 8 197 15
8 132 15 9 211 15
10 214 15
9 120 15
Tavg 181.4
10 148 15
Tavg 124.1

21

Depth of Cut (0.15 mm) Depth of Cut (0.15 mm)
1 174 15 1 169 15
2 176 15 2 173 15
3 188 15 3 183 15
4 191 15 4 196 15
5 184 15 5 199 15
6 195 15 6 204 15
7 201 15 7 208 15
8 205 15 8 217 15
9 209 15 9 245 15
10 214 15 10 247 15
Tavg 193.7 Tavg 204.1
Table 3

Depth of Cut (0.2mm) Depth of Cut (0.2mm)
Sr No. TmaxC Time Interval(s) Sr No. Tmax C Time Interval(s)
1 167 15 1 184 15
2 170 15 2 193 15
3 176 15 3 196 15
4 180 15 4 198 15
5 183 15 5 199 15
6 184 15 6 205 15
7 193 15 7 208 15
8 195 15 8 211 15
9 198 15 9 214 15
10 191 15 10 216 15
Tavg 183.7 Tavg 202.4
Table 7-1 List of Temperature Distribution Tables for Dry Machining (Grade 5 )

22
b) Ti-Alloy ( JIS Class 4 )

Sr No. Tmax C Time Interval (s) Sr No. Tmax C Time Interval (s)
1 104 15 1 106 15
2 107 15 2 108 15
3 112 15 3 116 15
4 116 15 4 123 15
5 117 15 5 129 15
6 121 15 6 134 15
7 135 15 7 141 15
8 143 15 8 147 15
9 148 15 9 155 15
10 152 15 10 157 15
Tavg 125.5 Tavg 131.6

1 113 15 1 111 15
2 115 15 2 117 15
3 127 15 3 123 15
4 129 15 4 128 15
5 133 15 5 134 15
6 137 15 6 145 15
7 146 15 7 153 15
8 158 15 8 155 15
9 161 15 9 158 15
10 165 15 10 167 15
Tavg 138.4 Tavg 139.1

23

Depth of Cut (0.2 mm) Depth of Cut (0.2mm)
Sr No. Tmax C Time Interval(s) Sr No. TmaxC Time Interval(s)
1 118 15 1 121 15
2 126 15 2 126 15
3 132 15 3 130 15
4 134 15 4 137 15
5 137 15 5 143 15
6 142 15 6 149 15
7 149 15 7 154 15
8 154 15 8 159 15
9 157 15 9 167 15
10 164 15 10 171 15
Tavg 141.3 Tavg 145.7
Table 7-2 List of Temperature Distribution Tables for Dry Machining (JIS Class 4)

24
7.1.2 Surface Hardness (HRC) (Rockwell Hardness C scale)
a) Ti-alloy (Grade 5)
Table 5
Sr No. 0.1mm 0.15mm 0.2mm Sr No. 0.1mm 0.15mm 0.2mm

1 54 46 45 1 34 50 60
2 54 44 42 2 54 43 61
3 42 61 62 3 44 55 42
4 53 64 43 4 61 44 60
Avg. 50.75 53.75 48 Avg. 48.25 48 55.75
Table 7-3 List of Hardness Tables for Dry Machining (Grade 5 )
b) Ti-alloy (JIS Class 4)
Table 6

1 12 12 13 1 11 12 13
2 13 13 14 2 13 14 14
3 12 14 13 3 14 13 13
4 14 13 15 4 13 14 15
Avg. 12.75 13 13.75 Avg. 12.75 13.25 13.75
Table 7-4 List of Hardness Tables for Dry Machining (JIS Class 4)

25
7.1.3 Surface Roughness
a) Ti alloy (Grade5)
These readings include (Ra, Rz & Rq values in (microns)
8
Speed (80 rpm)
7
Surface Roughness (microns)

6
5
Depth of Ra Rz Rq
Ra
Cut(mm) 4
Rz
0.1 1.5 7.217 1.767 3
Rq
2
0.15 1.657 7.287 1.898
1
0
0.2 1.537 7.144 1.806 Depth of 0.1 0.15 0.2
Cut
Graph 7-1 Surface Roughness Ti-alloy (Grade 5) (Dry) 80 rpm
8
Speed (120 rpm)
7
6
Depth of Ra Rz Rq 5
Cut(mm) Ra
0.1 1.6 7.434 1.868 4
Rz
3 Rq
0.15 1.666 7.215 1.921 2
1
0.2 1.553 6.886 1.796 0
Depth of Cut 0.1 0.15
Graph 7-2 Surface Roughness Ti-alloy (Grade 5) (Dry) 120 rpm

26
b) Ti-alloy (JIS class 4)
8
Speed (80 rpm)
7

6
Depth of Cut Ra Rz Rq 5
(mm) Ra
4
Rz
0.1 1.616 7.061 1.848 3
Rq
2
0.15 1.516 6.733 1.771 1
0
0.2 1.623 7.045 1.791 Depth of 0.1 0.15 0.2
Cut
Graph 7-3 Surface Roughness Ti-alloy (JIS Class 4) (Dry) 80 rpm
9
Speed (120 rpm)
8
7
(mm) Ra
5
0.1 1.729 7.939 2.016 4 Rz
3 Rq
0.15 1.459 6.633 1.715 2

1
0.2 1.543 7.348 1.826 0
Graph 7-4 Surface Roughness Ti-alloy (JIS Class 4) (Dry) 120 rpm

27
7.2 WET MACHINING
In dry cutting operations, the friction and adhesion between chip tool tend to be
higher, which causes higher temperatures, higher wear rates and, consequently,
shorter tool lives Up to this moment, completely dry cutting is not suitable for many
machining processes. Since cutting fluid is necessary to prevent the chips from
sticking to the tool and causing its breakage [4]. High temperature in cutting zone has
been traditionally tried to control by using cutting fluids. The coolant effect reduces
temperature in cutting zone and the lubrication action decreases cutting forces. Thus
the friction coefficient between tool and chip becomes lower in comparison to dry
machining [5] and [6]. The aims of cutting fluid applications were determined as
cooling and lubrication in metal cutting. In addition, cutting fluids can help to
disposal of the chips from hole and control chip formation. Because they decrease
contact length between chip and tool, and this situation has a positive effect on chip
breaking. Thus, they can help to achieve better tool life [7] and [8]. The cost of
cutting fluids is approximately 7 to 17% of the total cost in machining process [9].
Ascutting fluid is applied during machining operation, it removes heat by carrying it
away from the cutting tool/work-piece interface [10].
This cooling effect prevents the tool from exceeding its critical temperature
range beyond which the tool softens and wears rapidly [11]. Cutting fluids are used
throughout industry in many metal cutting operations and they are usually classified
into 3 main categories: neat cutting oils, water-soluble fluids and gases [12].
The major needs in machining are high material removal rate, good work surface
finish and low tool wear. These objectives can be achieved by reducing tool wear
using proper cooling system of the tool during machining. The main objective of
using cutting fluids in machining operations is the reduction of temperature in the
cutting region to increase tool life.
Photo 7-2 Experimental setup of wet machining

28
The purpose of using cutting fluids
The cutting fluids are used in machining operations in order to

(i) Reduce friction at the tool-chip and tool work- piece interfaces,
(ii) Cool both chip and tool, and
(iii) Remove chips which are formed during machining
Furthermore, they have a strong effect on the shearing mechanisms and,

consequently, on the work-part surface finish and tool wear [13] and [14]. The
positive effect of the use of fluids in metal cutting was first reported in 1894 by F.
Taylor [15], who noticed that by applying large amounts of water in the cutting area,
the cutting speed could be increased up to 33% without reducing tool life. Since then,
cutting fluids have been developed resulting in an extensive range of products
covering most work-piece materials and operations. According to Kress [16], the
costs associated with the use of cutting fluids represent approximately 17% of the
finished work-piece cost against 4% spent with tooling. Kwon [17], studied flank
wear by incorporating cutter temperature and physical properties of coating and work
materials. The objective of this paper is to investigate the effects of internal cooling
on the tool flank wear in orthogonal metal cutting. Diniz and Micaroni [4], carried
out other experiments in turning operations of AISI 1040 steel, also using coated
carbide tools and cutting conditions typical of finishing operations. Their goal was to
compare dry cutting with cutting with abundant
fluid at different feeds, cutting speed and tool nose radius.
The present work deals with experimental investigation in the role of cutting
fluids on cutting temperature, cutting forces, tool wears, and surface roughness value
in machining AISI- 1050 steel at industrial speed-feed condition by CVD coated
carbide TiC+AI2O3+TiN insert as compared to completely dry machining. This
study indicated that cutting fluid did not show a significant improvement on surface
roughness particularly when cutting tests with 0.8 mm nose radius were considered. In
fact, the roughness similarly deteriorated under wet machining in some of tests.
Cutting Fluid Used in our Project
We searched various places like lubricant shops, laboratories, internet,

manufacturers catalogues, etc. to know the procedure for selecting the cutting fluid
which is in sync with our requirements. Finally, after consulting many sources we
selected CASTROL Hysol MB 50
We found that this cutting fluid is a water soluble compound and its lubricating and
cooling specifications are in line with our projects requirement.

29
Procedure
The first step for wet machining is mixing of the cutting fluid and water in correct
proportion. For our requirement we mixed about 250 ml of cutting oil in
approximately about 4.75 liters of water to achieve a composition of about (5%
cutting oil + 95% water).
Now we switch on the coolant pump on our coolant sump and begin our work. We
take the temperature readings as discussed earlier from predetermined intervals of
time say (15 sec).
We also determine the flow rate maintain it as closely as possible to rule out any
spikes or undershoots in temperature recordings.
Wet Machining
a) Ti-alloy (grade5)

1 39.1 15 1 35.8 15
2 40.4 15 2 36.1 15
3 41.6 15 3 36.3 15
4 42.4 15 4 36.5 15
5 44.3 15 5 36.6 15
6 47.7 15 6 36.9 15
7 49.5 15 7 36.6 15
8 51.7 15 8 36.7 15
9 55.9 15 9 36.7 15
10 69.7 15 10 38.3 15
Tavg 48.23 Tavg 36.65

30

Sr No. Tmax Time Interval(s) Sr No. Tmax C Time Interval (s)
1 46.8 15 1 35.1 15
2 47.3 15 2 36.4 15
3 47.7 15 3 36.9 15
4 48.1 15 4 39.4 15
5 48.8 15 5 40.4 15
6 49.7 15 6 41.5 15
7 50.9 15 7 42.9 15
8 51.3 15 8 43.1 15
9 61.9 15 9 43 15
10 71.6 15 10 43.6 15
Tavg 52.41 Tavg 40.23

1 37.5 15 1 36.2 15
2 37.7 15 2 36.6 15
3 38.1 15 3 37.4 15
4 38.8 15 4 37.8 15
5 38.9 15 5 39 15
6 39 15 6 41.6 15
7 42 15 7 46.1 15
8 42.6 15 8 46.9 15
9 43.8 15 9 48.7 15
10 66.9 15 10 60.3 15
Tavgz 42.53 Tavg 43.06
Table 7-5 List of Temperature Distribution Tables for Wet Machining (Grade 5)

31
b.) Ti-alloy (JIS Class4)

Sr No. TmaxC Time Interval (s) Sr No. TmaxC Time Interval (s)
1 37 15 1 38 15
2 43 15 2 41 15
3 44 15 3 45 15
4 47 15 4 47 15
5 48 15 5 48 15
6 51 15 6 52 15
7 53 15 7 54 15
8 57 15 8 55 15
9 59 15 9 59 15
10 60 15 10 62 15
Tavg 49.9 Tavg 50.1

Sr No. Tmax C Time Interval (s) Sr No. TmaxC Time Interval (s)
1 37 15 1 38 15
2 39 15 2 40 15
3 44 15 3 43 15
4 47 15 4 45 15
5 49 15 5 47 15
6 50 15 6 51 15
7 52 15 7 53 15
8 55 15 8 57 15
9 59 15 9 58 15
10 61 15 10 64 15
Tavg 49.3 Tavg 49.6

32

Sr No. TmaxC Time Interval (s) Sr No. Tmax C Time Interval(s)
1 39 15 1 42 15
2 43 15 2 46 15
3 45 15 3 49 15
4 45 15 4 51 15
5 47 15 5 55 15
6 50 15 6 58 15
7 53 15 7 59 15
8 57 15 8 61 15
9 60 15 9 64 15
10 65 15 10 67 15
Tavg 50.4 Tavg 55.2
8 Table 7-6 List of Temperature Distribution Tables for Wet Machining (JIS Class 4)

33

Table 9
a) Ti-alloy (Grade5)

Sr No. 0.1mm 0.15mm 0.2mm
Sr No. 0.1mm 0.15mm 0.2mm
1 64 48 70
1 60 45 65
2 60 61 67
2 52 55 67
3 48 53 64
3 61 50 58
4 58 39 63 4 60 57 62
Avg. 57.75 47.25 63.25 Avg. 58 54.75 65.75
Table 10
Table 7-7 List of Hardness Tables for Wet Machining ( Grade 5 )
1 11 12 13
1 13 12 12
2 14 14 14
2 11 13 14
3 13 12 12 3 13 15 13
4 12 14 12 4 12 13 15
Avg. 12.25 12.75 12.5 Avg. 12.5 13.5 13.75
Table 7-8 List of Hardness Tables for Wet Machining (JIS Class 4)

34
8
Speed (80 rpm) 7

6
5
Depth of Cut Ra Rz Rq Ra
4
(mm) Rz
0.1 1.616 7.061 1.848 3
Rq
2
0.15 1.516 6.733 1.771 1
0
0.2 1.623 7.045 1.791 Depth of 0.1 0.15 0.2
Cut
Graph 7-5 Surface Roughness Ti-alloy (Grade 5) (Wet) 80 rpm
9
Speed (120 rpm)
8
7
6
Depth of Cut Ra Rz Rq
5 Ra
(mm)
4 Rz
0.1 1.729 7.939 2.016
3 Rq
0.15 1.459 6.633 1.715 2

1
0.2 1.543 7.348 1.826 0
Graph 7-6 Surface Roughness Ti-alloy (Grade 5) (Wet) 120 rpm

35
8
Speed (80 rpm)
7

6
5
Depth of Cut Ra Rz Rq 4 Ra
(mm)
3 Rz
0.1 1.616 7.061 1.848
2 Rq
0.15 1.516 6.733 1.771 1

0
Depth of 0.1 0.15 0.2
0.2 1.623 7.045 1.791 Cut
Graph 7-7 Surface Roughness Ti-alloy (JIS Class4) (Wet) 80 rpm
8
Speed (120 rpm)
7
Ra
(mm) 4
Rz
0.1 1.729 7.939 2.016
3 Rq
2
0.15 1.459 6.633 1.715
1
0.2 1.543 7.348 1.826 0
Graph 7-8 Surface Roughness Ti-alloy (JIS Class4) (Wet) 120 rpm

36
The immediate advantages of using a cutting fluid are
1. The coolant helps in breaking up chips and removing them from the cutting area
more efficiently, which means the cutting tool spent less time for breaking metal
chips.
2. The cutting fluid has significantly reduced the amount of heat and friction at the
point where a tool cuts into a metal work piece.
3. The results of the present work indicate substantial reduction in tool wear, which
enhanced the tool life; this may be mainly attributed to reduction in cutting zone
temperature and favorable change in the chip-tool interaction.
4. The heat is carried away very effectively when a cutting fluid is used and it
prevents the temperature from going above the critical temperature of the tool ,
thereby prolonging the life of the tool.
5. If the cutting fluid is directed at the tool chip interface we obtain a considerable
reduction in temperature which then helps in easy and quick chip removal and the
length of the chip is also shortened.
6. It is easier to dispose of discontinuous chips.

37
7.3 VTJA (VORTEX TUBE JET ASSISTED MACHINING)
Figure 7-1 Working Principle of Vortex Tube
Vortex tube is a simple device that is used to produce cooling effect. It has no
moving parts. The vortex tube utilizes ambient air compressed to high pressure. The
compressed air entering the vortex tube splits into two air streams at slightly above
atmospheric pressure; one is hot and other is cold. It has been observed that when the
compressed gas is injected into the tube tangentially at a high velocity, it starts
rotating and moving to the hot end, i.e. the other end from the injection. A small
portion of the flow escapes from the gap between the control plug and the tube with
higher temperature than at the injection point, which in the literature is referred to as
the hot stream. The other part of the flow is then forced back by the control plug and
moves to the cold end through the central region of the tube.
This central flow is then exhausted from the central exit near the injection point,
at a lower temperature than at the injection, and forms the cold stream. Thus, the
injected flow is divided into two flows with different temperatures, and this
phenomenon is well known as the temperature separation in a vortex tube. This cold
air can be used for various applications. Similarly the hot air can also be used to serve
some purposes. The volume and temperatures of these streams are adjustable with a
valve built into a hot air exhaust. Cold airflow and cold air temperature are easily
controlled by adjusting the slotted valve in the hot air outlet. Opening the valve
reduces the cold airflow and the cold air temperature. Closing the valve increases the
cold air flow and cold air temperature. The percentage of air directed to the cold outlet
of the vortex tube is called the cold fraction. In most applications, a cold fraction of

38
80% produces a combination of cold flow rate and temperature drop that maximize
refrigeration, or Btu/hr output of a vortex tube. While low cold fractions (less than
50%) produce lowest cold air flow rate sacrificed to achieve that.
VELOCITY PROGRESSION FOR A VTJA TUBE (2-NOZZLE)
Figure 7-2 Flow of Compressed Air in Vortex Tube
Principle of Operation
Compressed air is supplied to the vortex tube and passes through nozzles that are
tangent to an internal counter bore. These nozzles set the air in a vortex motion. This
spinning stream of air turns 90 degrees and passes down the hot tube in the form of a
spinning shell, similar to a tornado. A valve at one end the tube allows some of the
warmed air to escape. What does not escape, heads back down the tube as a second
vortex inside the low pressure area of the larger vortex. Angular momentum has been
lost from the inner vortex. The energy that is lost shows up as heat in the outer vortex.
Thus the outer vortex becomes warm and the inner vortex is cooled.
The governing equation of a vortex tube is known as Eulers turbine /work equation
which is given as-
.
=

Where, T is the total, or stagnation temperature of the rotating gas at radial position r
, the absolute gas velocity as observed from the stationary frame of reference is
denoted with v ; the angular velocity of the system is and cp is the isobaric heat
capacity of the gas.

39
Procedure
In this case we have used a 2 nozzle Ranque-Hilsch vortex tube which will be
henceforth mentioned as VTJA tube.
Here also we are maintaining the same cutting parameters as mentioned above, but we
are employing compressed air as a cooling media by adopting VTJA tube. For this
purpose we used the compressor which was available in our workshop whose
maximum rated pressure is about- 8 kg/cm2.
We first setup the lathe according to the specified cutting parameters and then we
started the compressor and after a pressure of about 6 -7 kg/cm2 is achieved we start
opening the delivery valve on the compressor slowly and maintain the pressure in the
range of about 3-5 kg/cm2 within the system.
The cold air coming out of the exit is directed to the chip-tool interface and the
photographs are taken with the thermal camera at predetermined intervals of time say
(10 secs).
Photo 7-3 Experimental setup of VTJA machining

40
VTJA machining
a) Ti-alloy (grade5)

Sr No. Tmax(C) Time Interval(s) Sr No. Tmax(C) Time Interval(s)
1 46.9 15 1 54.6 15
2 64.1 15 2 55 15
3 65 15 3 56.9 15
4 69 15 4 60.5 15
5 86.6 15 5 61.4 15
6 89.3 15 6 64.6 15
7 89.9 15 7 70.4 15
8 99 15 8 75.2 15
9 103 15 9 87.3 15
10 107 15 10 88.3 15
Tavg 81.98 Tavg 67.42

1 47 15 1 74.6 15
2 53.8 15 2 77.5 15
3 58.5 15 3 79.7 15
4 61.4 15 4 80.5 15
5 63.4 15 5 83.9 15
6 64.2 15 6 84.4 15
7 68.9 15 7 85.5 15
8 69.2 15 8 88.2 15
9 71.5 15 9 95.8 15
10 75.9 15 10 97.2 15
Tavg 63.38 Tavg 84.73

41

Sr No. Tmax(C) Time Interval (s) Sr No. Tmax(C) Time Interval(s)
1 49.9 15 1 44.9 15
2 53.2 15 2 45 15
3 55.7 15 3 62.9 15
4 59.2 15 4 69.6 15
5 61.4 15 5 70 15
6 64.5 15 6 75.6 15
7 66.8 15 7 79.1 15
8 68.2 15 8 85.4 15
9 74.3 15 9 87.7 15
10 77.7 15 10 89.4 15
Tavg 63.09 Tavg 70.96
Table 11
Table 7-9 List of Temperature Distribution Tables for VTJA Machining (Grade 5)
b) Ti-alloy (JIS class 4)

1 56 15 1 56 15
2 58 15 2 58 15
3 61 15 3 61 15
4 64 15 4 64 15
5 67 15 5 67 15
6 69 15 6 69 15
7 72 15 7 72 15
8 75 15 8 75 15
9 76 15 9 76 15
10 77 15 10 77 15
Tavg 67.5 Tavg 67.5

42
Speed (80 rpm)

Depth of Cut (0.15mm)
Sr No. Tmax Time Interval(s) Speed (120 rpm)
(C) Depth of Cut (0.15mm)
1 57 15 Sr No. Time Interval(s)
Tmax
2 60 15 (C)
1 55 15
3 62 15
2 61 15
4 63 15
3 64 15
5 66 15 4 67 15
6 68 15 5 69 15
7 71 15 6 72 15
8 74 15 7 73 15
9 76 15 8 76 15
9 77 15
10 77 15
10 78 15
Tavg 67.4
Tavg 69.2

1 61 15 1 60 15
2 63 15 2 64 15
3 67 15 3 67 15
4 72 15 4 71 15
5 76 15 5 74 15
6 77 15 6 77 15
7 79 15 7 80 15
8 82 15 8 83 15
9 83 15 9 86 15
10 85 15 10 87 15
Tavg 74.5 Tavg 74.9
Table 7-10 List of Temperature Distribution Tables for VTJA Machining (JIS Class 4)

43
Table 13
VJTA Machining Speed VJTA Machining Speed

(80 rpm) (120 rpm)
Sr 0.1mm 0.15mm 0.2mm Sr 0.1mm 0.15mm 0.2mm
No. No.
1 49 56 61 1 51 57 63
2 56 49 63 2 48 56 55
3 58 52 53 3 62 57 59
4 48 58 64 4 56 63 60
Avg. 52.75 53.75 60.25 Avg. 54.25 58.25 59.25
Table 7-11 List of Hardness Tables for VTJA Machining (Grade 5)
b) Ti alloy (JIS Class4)
VJTA Machining Speed VJTA Machining Speed

(80 rpm) (120 rpm)
1 11 12 11 1 12 13 12
2 13 13 14 2 14 14 15
3 12 11 14 3 15 13 14
4 14 13 14 4 13 12 13
Avg. 12.5 12.25 13.25 Avg. 13.5 13 13.5
Table 14
Table 7-12 List of Hardness Tables for VTJA Machining (JIS Class 4)

44
a) Ti alloy (Grade 5)
16
Speed (80 rpm) 14

12
(mm) 10
Ra
8
0.1 4.04 15.138 4.468 Rz
6
Rq
4
0.15 1.178 6.554 1.444
2
0
0.2 1.415 7.687 1.717 Depth of 0.1 0.15
Cut
Graph 7-9 Surface Roughness Ti-alloy (grade 5) (VTJA) 80 rpm
Speed (120 rpm)

9
8
(mm)
6
Ra
5
0.1 1.411 5.866 1.638 Rz
4
3 Rq
0.15 1.06 5.945 1.295 2
1
0.2 1.484 8.164 1.816 0

Graph 7-10 Surface Roughness Ti-alloy (grade 5) (VTJA) 120 rpm

45
16
Speed (80 rpm)
14

12
10
(mm) Ra
0.1 4.04 15.138 4.468 8
Rz
6 Rq
0.15 1.178 6.554 1.444 4
2
0.2 1.415 7.687 1.717
0
Graph 7-11 Surface Roughness Ti-alloy (JIS Class4) (VTJA) 80 rpm
9
Speed (120 rpm)
8
7
(mm)
5 Ra
0.1 1.411 5.866 1.638 4 Rz

3 Rq
0.15 1.06 5.945 1.295 2

1
0.2 1.484 8.164 1.816 0
Graph 7-12 Surface Roughness Ti-alloy (JIS Class4) (VTJA) 120 rpm

46
8 RESULTS
8.1 Temperature distribution
Description :- 120 RPM, depth of cut-0.1 mm , Ti-alloy (Grade 5)
250
200
Temperature (C)
150
100 Dry
50 Wet
VJTA
0
Time interval (s)
Description :- 120 RPM , depth of cut-0.1 mm, Ti-alloy (JIS Class 4)
180
160
140
Temperature (C)
120
100
80
Dry
60
40 Wet
20 VJTA
0
Time interval (s)
Graph 8-1 Temperature of tool chip interface at fixed intervals of time
Remarks- By comparing both the graphs we can say that wet machining has
performed much better during wet machining when compared to other 2 machining
conditions of Dry, and VTJA.

47
8.2 Surface Hardness
Description :- 120 RPM, depth of cut-0.1 mm , Ti-alloy(Grade 5)
70
60
Rockwell hardness (HRC)
50
40
Dry
30
Wet
20 VJTA
10
0
10 30 50 70
Distance from one end (mm)
Description :- 120 RPM , depth of cut-0.1 mm, Ti-alloy(JIS Class4)
16
14
Rockwell hardness (HRC)
12
10
8 Dry
6 Wet
4 VJTA
2
0
10 30 50 70
Distance from one end (mm)
Graph 8-2 Rockwell hardness as measured from one end
Remarks
We can infer from the above graphs that when the bars are turned under wet
condition the hardness peaks at some places, but when VTJA machining is utilized,
the hardness is maintained within a certain range without giving any sudden rise in
hardness at any point.

48
8.3 Micro Structural Investigation
Description - Speed-120 RPM,
Machining type - Dry turning , Depth of cut - 0.1 mm, Ti-alloy(Grade5)
TEST REPORT
Sample Description - Sample No 1, Dry Machining (0.1Depth @120 Rpm)
The above samples have been tested and results are as below.
Magnification - 400 x Etchant- HF+HNO3
Figure 8-1 Micro-structure for Dry Machining (0.1Depth @120 Rpm)
Remarks-
It shows fine alpha grains ()(light areas) in a matrix of untransformed Beta ()
(gray areas).

49
Machining type - Wet turning , Depth of cut - 0.1 mm, Ti-alloy(Grade5)
TEST REPORT
Sample Description - Sample No 2, Wet Machining (0.1Depth @120 Rpm)
Figure 8-2 Micro-structure for Wet Machining (0.1Depth @120 Rpm)
Remarks-
It shows elongated alpha grains () (light areas) in a matrix of beta ()(partially

transformed.)

50
Machining type - VTJA turning , Depth of cut - 0.1 mm, Ti-alloy(Grade5)
TEST REPORT
Sample Description - Sample No 3, VTJA Machining (0.1Depth @120 Rpm)
Figure 8-3 Micro-structure for VTJA Machining (0.1Depth @120 Rpm)
Remarks-
It shows elongated alpha grains () (light) and Inter granular beta () gray (mottled or
outlined). The matrix is transformed beta.

51
9 CONCLUSION
We have consulted a large number of articles, research papers, web links, hard copies,
journals on the above said topic and found that our project topic is a very pressing
topic in the critical industries such as viz. Aerospace (civilian and military) ,Defense,
Nuclear, Petrochemical and tooling industries.
Also one of the most important consumers of this metal is companies making
Gas Turbine engines as the gas exhaust temperature is (>1500 K) here titanium is
invaluable as nozzles.
As the above said industries have the lions share in the consumption of
titanium (>65%) it is quite satisfying on our part to find out a solution that benefits
them. It is said that the machinability of Titanium is one of the poorest with
machinability index (MI) of about 45.
From our studies we confirmed that the titanium alloy in itself is poorly
machinable, and it results in much shorter tool life. Hence, we found that out of the
three cooling methods employed, VTJA (Vortex tube jet assisted machining) is the
most efficient. During the actual performance of the project we found that during Dry
machining of Ti-alloy both (grade 5 and JIS Class 4), the heat generation and the
retention i.e the heat tends to remain in the concerned region for a longer time which
is as expected because here air is assumed to be assumed to be moving with less
velocity. As the velocity of air is less, it falls under the case of free convection in
gases.
In the second case of Wet machining of the titanium, the heat generated is
carried away by the falling stream of cutting fluid whose temp being
approx.(35C).During the experiment it was observed that the there has been a very
drastic change in the heat signature of the tool-chip interface, and it was much lesser
in comparison to the earlier case. During the last case of VTJA machining, as the
coolant media employed was cold air issuing from a VTJA tube, we found that it is
the most efficient coolant media and removes heat generated very quickly thereby
saving the tool from getting burnt. The biggest advantage which we are getting in this
case is that, in spite of efficient cooling, there is no adverse effect on the metallurgy of
the alloy as found from the micro structural studies, because as the temperature is

52
maintained within a proper zone, chance of oxidation reduces and we are achieving it
without using any cutting fluid, which most of them use mineral oil as base and their
disposal being harmful to the environment. They also add to the machining cost of the
industry and are commonly included under overhead cost. We can easily implement
this in industries where nowadays it is very common to have high pressure (4-5
kg/cm2) air pipelines, as they are commonly used to run the pneumatic tools.
The VTJA system can be retrofitted on the existing machining setups, without
disturbing them. It can be utilized in machining of extremely precise components by
performing the machining under controlled atmosphere and using inert gases.
Thus, we conclude that VTJA machining is the most beneficial considering the
parameters under which our project was undertaken.There is also a huge scope for
further research in the foresaid topic, by trying out different combinations of cutting
tools, different machining processes, design of VTJA nozzle, etc.

53
10 Bibliography
[1] Kiran Devade, A.T. Pise, V.M. Kale Balaji Nelge, "Thermal and Metallographic
Investigation for H13A and AISI1050 using VTJA," in 5th International & 26th
All India Manufacturing Technology, Design and Research Conference
(AIMTDR 2014), Guwahati, january 2014, pp. 12-14.
[2] J. P. Davim and A.J.R. Loureiro C. Veiga, "REVIEW ON MACHINABILITY

OF TITANIUM ALLOYS," January 2013.
[3] Mitsuo Niinomi, "Recent research and development in titanium alloys for
biomedical," Science and Technology of Advanced Materials 4, vol. XII, no. 16,
pp. 445-454, Feb 2003.
[4] Bharatkumar M. Sutaria & Dhananjay V. Bhatt Chakradhar Bandapalli, "High

Speed Machining of Ti-alloys- A Critical Review,".
[5] (2004, April) wikipedia. [Online]. https://en.wikipedia.org/wiki/Titanium
[6] (2007) Aerospace metals inc. [Online].

http://asm.matweb.com/search/SpecificMaterial.asp?bassnum=mtp641
[7] (2006) Fluke. [Online]. http://www.fluke.com/fluke/inen/thermometers/fluke-

568-2-566-2.htm?pid=56090
[8] H.A. Salaam, T.M.Y.S. Tuan Ya, S.Y. Phoon, C.F. Tan and M.A. Akiah Zahari
Taha1, "VORTEX TUBE AIR COOLING: THE EFFECT ON SURFACE
ROUGHNESS AND POWER CONSUMPTION IN DRY TURNING,"
International Journal of Automotive and Mechanical Engineering (IJAME), July-
Dec 2013.
[9] Surftest-210 SJ manual Mitutoyo. (2012) Mitutoyo. [Online].

https://www.mitutoyo.co.in/media/pdf/Form/SJ-210.pdf
[10] S. Narendranath and S. Basavarajappa M. Manjaiah, "application of EDM and

WEDM on titanium materials ," 2013.
[11] guidelines for selection of lubricants Castrol. (2009) castrol.com. [Online].

https://thelubricantoracle.castrol.com/product/hysol-mb-50/industrial/en-IN
[12] User Manual FLIR-E30. (2012, March) FLIR-IR devices. [Online].

http://www.autoid.ro/media/E30.pdf

54
[13] Article on machining problems of titnium and their solution. (2009, April)
practicalmachinist. [Online]. http://www.practicalmachinist.com/vb/cnc-
machining/tips-cutting-titanium-6al-4v-124743/
[14] Suhas S. Joshi, "Machinability of titanium alloys under various machining," in

Advances in Light weighting Technology - Design, Materials, Manufacturing
Applications, Pune,INDIA, 2012, pp. 1-5.

55

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A Dissertation on

MAINAK GHOSH B120520870

Mechanical Engineering Department

Indira College of Engineering &

have successfully completed the Dissertation entitled Experimental

Prof. B.D.Nelge Prof. M. G. Bhong Dr. Sunil Admuthe

We are heartily thankful to Prof. Balaji D. Nelge whose encouragement,

We would like to thank Prof. Mahesh G. Bhong (HOD, Mechanical

ADITYA NARAYAN TIWARI

Table 4-1 Periodic Table ................................................................................................... 6

Graph 7-1 Surface Roughness Ti-alloy (Grade 5) (Dry) 80 rpm .............................. 26

Velocity vector (m/s)

Angular velocity (rad/s)

r - Position vector (m)

Cp Specific heat at constant pressure (J/Kg.K)

HR - Rockwell Hardness Number

d Depth (from the zero load point)

Ra - Roughness Average (microns.)

Rq - Root Mean Square (RMS) roughness (microns.)

Rz Average maximum height of profile (microns.)

This article focuses on machinabilty of titanium alloys under

Titanium is a poor conductor of heat. Heat, generated by the cutting action,

ICEM, BE (Mechanical Engineering) 2016-17

1.1 Objectives to be accomplished

1. Metallographic study of difficult to machine materials.

1.2 Parameters to be covered

1. Machining various Ti alloy grades of Difficult to machine materials.

ICEM, BE (Mechanical Engineering) 2016-17

On going through the research work conducted by ( Balaji Nelge, Kiran

ICEM, BE (Mechanical Engineering) 2016-17

Bharatkumar M. Sutaria & Dhananjay V. Bhatt carried out work on

ICEM, BE (Mechanical Engineering) 2016-17

The machining of hard material (Titanium Alloy) is generally carried by Non

Photo 3-1 Experimental Setup

ICEM, BE (Mechanical Engineering) 2016-17

Table 4-1 Periodic Table

Although commercially pure titanium has acceptable mechanical properties

ICEM, BE (Mechanical Engineering) 2016-17

Titanium alloys are generally classified into four main categories:-

Generally, beta-phase titanium is the more ductile phase and alpha-phase is

ICEM, BE (Mechanical Engineering) 2016-17

ICEM, BE (Mechanical Engineering) 2016-17

5 DESIGN OF EXPERIMENTAL SETUP (CAD MODEL)

Figure 5-1 Isometric Cad Model

Figure 5-2 Different Views

ICEM, BE (Mechanical Engineering) 2016-17

6.1 Resources required in our project

6.1.1 Work piece Material

Photo 6-1 Titanium alloy bar

ICEM, BE (Mechanical Engineering) 2016-17

Photograph of a new 2-sided CBN insert

Photo 6-2 Effect of Machining on CBN insert

ICEM, BE (Mechanical Engineering) 2016-17

6.1.3 Selection of Lathe

There are 2 types of lathes available in our workshop-

1) Belt driven Lathe

2) All gear driven lathe

Photo 6-3 TRUMAC 6082 medium duty lathe

ICEM, BE (Mechanical Engineering) 2016-17

6.1.4 Infrared Thermometer

Photo 6-4 Infrared Thermometer

The analysis of Thermal distribution during machining of titanium alloy bar by

Figure 6-1 Temperature measurement using Infrared Thermometer

ICEM, BE (Mechanical Engineering) 2016-17