10 - Chapter 5 PDF

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CHAPTER 5
RESULTS AND DISCUSSION
5.1 INTRODUCTION
The quality and performance of a machined component are directly

related to the surface integrity, which includes the topological parameters
(surface roughness and other characteristic surface topographic features),
specific mechanical properties (residual stresses, hardness, etc.), and
metallurgical states of the work material during processing (Outeiro et al
2008).
In order to maintain and/or improve the reliability of aerospace

components, it is first essential to be aware of the possible damage or surface
alterations that can be imparted to a material when it is machined. Therefore,
the present research work focuses on the investigations of the cutting force,
temperature rise at tool tip, surface roughness, flank wear and the most widely
used surface integrity characteristics such as residual stress, and
microhardness, that are generated on the machined surface, while machining
the nimonic C-263 super alloy.
5.2 EFFECT OF MACHINING PARAMETERS ON RESPONSES

IN THE TURNING OF NIMONIC C-263 ALLOY
In this work the effect of machining parameters in the turning of

nimonic C-263 alloy on the machining characteristics was studied under
different levels of machining parameters using the three inserts, as presented
170
in chapter 3, Table 3.3 on a nagamati 175 lathe. It is observed that the

machining parameters such as cutting speed, feed rate and depth of cut have
greater influence on the responses in turning of this alloy. The responses
considered for the present investigations are (a) Cutting force, (b) cutting
temperature at tool tip, (c) surface roughness, (d) flank wear and (e) the
surface integrity characteristics, viz., residual stress, microhardness.
5.3 EFFECT OF MACHINING PARAMETERS ON THE

RESPONSES IN TURNING NIMONIC C- 263 ALLOY
USING PVD COATED CARBIDE INSERT.
The effect of the machining parameters on the responses such as

cutting force, temperature at tool tip, surface roughness and flank wear were
evaluated and analysed in turning nimonic C-263 alloy using PVD coated
carbide insert.
5.3.1 Effect of Machining Parameters on the Cutting Force (Fz)

Using PVD Coated Carbide Insert.
Figure 5.1 (a-c) illustrates the contour maps in the feature plane for
the cutting force at different level of depths of cut. These response contours
can help in the prediction of the cutting force at any zone of the experimental
domain.
171
(a) Cutting force at 0.50 mm depth of cut
(b) Cutting force at 0.75 mm depth of cut
(c) Cutting force at 1 mm depth of cut
Figure 5.1 (a-c) Cutting Force Contours in Velocity- Feed Plane at

Different Depths of cut for PVD coated carbide Insert
172
Figure 5.2 (a-c) illustrates the 3D response surface plots for the
cutting force. These surface plots are drawn, using the developed RSM model
by varying the two different parameters and keeping the third parameter at the
middle level. It is clear from these figures that the magnitude of the cutting
force component is high at lower level of cutting speed and higher level of
feed rate.
(a) 3D response surface plots for the cutting force at 0.75 mm depth of cut
(b) 3D response surface plots for the cutting force at 33 m/min cutting speed
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(c) 3D response surface plots for the cutting force at 0.102 mm/rev feed rate
Figure 5.2 (a-c) 3D Response Surface Plots for the Cutting Force using
PVD coated carbide Insert
The cutting force is reduced when the level of depth of cut and feed
rate is reduced. It is found that the cutting force (Fz) varies between the range
of 340-585 N in machining nimonic C-263 alloy under different level of
machining parameters using PVD coated carbide insert. The influence of the
machining parameters on the cutting force is illustrated in Figures 5.3-
5.5.From Figure 5.3, it is observed that the magnitude of the cutting force
tends to increase when the feed rate increases, for all levels of cutting speed.
Further it is observed that, the maximum cutting force of 486 N is generated
at a higher level of feed rate and a middle level cutting speed.
550
500
450
400
350 Cutting speed = 22 m/min
Cutting speed = 54 m/min
250
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.3 Effect of Feed rate on Cutting Force at Different Cutting

Speeds
174
From Figure 5.4, it is observed that the maximum of the cutting

force generated is 501 N, at a lower level of cutting speed and a higher level
of depth of cut .The magnitude of the cutting force component tends to
increase at a low cutting speed and at all levels of the depth of cut. It is
observed that the magnitude of the cutting forces was high at a lower and
middle level of cutting speed than higher level of cutting speed. This may be
attributed due to the high coefficient of friction between the tool and the work
material, compared to that at a higher cutting speed. The generation of
temperature is high at a higher cutting speed, which softens the work material,
and the cutting force thus decreases.
550
500
450
400
350 depth of cut = 0.50 mm
depth of cut = 0.75 mm
300 depth of cut = 1 mm
250
22 33 54
Cutting speed (m/min)
Figure 5.4 Effect of Cutting Speed on Cutting Force at Different

Depths of Cut
Figure 5.5 shows that the magnitude of the cutting force tends to
increase, when the feed rate and depth of cut increases. The maximum cutting
force of 499 N is observed at a higher level of depth of cut and feed rate. At a
higher feed rate the cutting force increases as the flank wear increases, which
are evidently seen in Figure 5.6. The increase in the flank wear at a higher
feed rate creates the damage on the cutting edge, producing the abrasion
between the tool edge and work piece surface, thus the generation of the
cutting force is also high.
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550
500
450
400
350 feed rate = 0.051 mm/rev
feed rate = 0.102 mm/rev
250
0.5 0.75 1
Depth of cut (mm)
Figure 5.5 Effect of Depth of Cut on Cutting Force at Different Feed

Rates
550 0.3
500
0.2
450
0.1
400 Cutting force
flank wear
350 0
0.051 0.102 0.143
Feed rate (mm/rev)
Figure 5.6 Effect of Feed Rate on Cutting Force and Flank Wear at
cutting speed of 33 m/min and 0.75 mm depth of cut
5.3.2 Effect of Machining Parameters on the Cutting Temperature at

Tool Tip Using PVD Coated Carbide Insert.
Figure 5.7 (a-c) illustrates the contour maps in feature plane for the
temperature at tool tip at different depths of cut. These response contours can
help in the prediction of the temperature rise at tool tip at any zone of the
experimental domain.
176
(a) Temperature at tool tip at 0.50 mm depth of cut
(b) Temperature at tool tip at 0.75 mm depth of cut
(c) Temperature at tool tip at 1 mm depth of
Figure 5.7 (a-c) Temperature at tool tip contours in velocity- feed plane
at different depths of cut for PVD Coated Carbide Insert
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temperature rise at tool tip. These surface plots are drawn, using the
developed RSM model by varying the two different parameters and keeping
the third parameter at the middle level. It is clear from these figures that the
magnitude of the temperature rise at tool tip is high at high cutting speed and
at a high feed rate.
(a) 3D response surface plots for the temperature at tool tip at 0.75 mm
depth of cut
(b) 3D response surface plots for the temperature at tool tip at 33 m/min
cutting speed
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(c) 3D response surface plots for the temperature at tool tip at 0.102
mm/rev feed rate
Figure 5.8 (a-c) 3D Response Surface Plots for the Temperature at

Tool Tip using PVD Coated Carbide Insert
The temperature at tool tip is reduced when the level of depth of cut
and feed rate is reduced. It is found that the temperature at tool tip varies
between the range of 300-600°C in machining nimonic C-263 alloy under
different levels of machining parameters using the PVD coated carbide insert.
Further the effects of machining parameters on temperature rise at the tool tip
during machining nimonic C-263 alloy are shown in the Figures 5.9 - 5.11.
From Figure 5.9, it is observed that the magnitude of the temperature rise at
tool tip tends to increase when the feed rate and cutting speed increases and
also, it is observed that the maximum temperature of 583 C is generated at a
higher level feed rate and a high level cutting speed. The results indicated that
the increase of feed rate increases the temperature at the tool tip. At increasing
cutting speed and feed rate, the concentration of higher temperature very close
to the cutting edge causes the notching and flank wear.
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600
550
500
450
400
250
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.9 Effect of feed rate on temperature at tool tip at different

cutting speed
From Figure 5.10, it is observed that the maximum temperature

rise at tool tip is 556 C at a higher level cutting speed and a higher level of
depth of cut .The temperature rise at tool tip tends to increase when the level
of cutting speed and depth of cut increases.
600
550
500
450
400
250
22 33 54
Figure 5.10 Effect of Cutting Speed on Temperature at Tool Tip at
Different Depths of Cut
From Figure 5.11, it is observed that the temperature tends to

increase, when the level of the feed rate and depth of cut increases. The
maximum of temperature rise at the tool tip of 558 C is observed at higher
level of depth of cut and feed rate.
180
600
550
500
450
400
250
0.5 0.75 1
Depth of cut (mm)
Figure 5.11 Effect of Depth of Cut on Temperature at Tool Tip at

Different Feed Rate
From Figures 5.9-5.11, it is observed that the cutting temperature

increases at the increasing the level of cutting speed, feed rate and depth of
cut. The generation of heat and temperature in the shear zone is highly
dependent on the machining parameters. At high level of machining
parameters, the strain hardening rate due to the rise in temperature and the
strain rate in the shear zone are relatively high. Due to these reasons the
temperature rise between the tool - chip interface is more.
5.3.3 Effect of Machining Parameters on the Surface Roughness

Using PVD Coated Carbide Insert.
Figure 5.12 (a-c) illustrates the contour maps in feature plane for
the surface roughness at different depths of cut. These response contours can
help in the prediction of the surface roughness at any zone of the experimental
domain.
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(a) Surface roughness at 0.50 mm depth of cut
(b) Surface roughness at 0.75 mm depth of cut
(c) Surface roughness at 1 mm depth of cut
Figure 5.12 (a-c) Surface Roughness Contours in Velocity- Feed Plane at

Different Depths of Cut for PVD Coated Carbide Insert
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surface roughness. These surface plots are drawn, using the developed RSM
model by varying the two different parameters and keeping the third
parameter at the middle level. It is clear from these figures that the magnitude
of the surface roughness is high at low cutting speed and at a high feed rate.
The surface roughness is reduced when the level of cutting speed is increased.
(a) 3D response surface plots for the surface roughness at 0.75 mm depth of cut
(b) 3D response surface plots for the surface roughness at 33 m/min

cutting speed
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(c) 3D response surface plots for the surface roughness at 0.102 mm/rev
feed rate
Figure 5.13 (a-c) 3D Response Surface Plots for the Surface Roughness
using PVD Coated Carbide Insert
It is found that the surface roughness varies between the range of

1.25-2.93 µm in machining nimonic C-263 alloy under different levels of
machining parameters using the PVD coated carbide insert. From Figure 5.14,
it is seen that with the increase in the feed rate, the surface roughness
increases for all cutting speeds. This may be attributed due to that at higher
feed rate, the height of the ridges (roughness) is increased, thus contributing
to higher surface roughness. Along with the effect of the feed rate and
geometry of the cutting edge, the roughness of the machined surface is also
affected by the chip formation process, which includes, the properties of the
metal being machined and elastic and plastic deformation of the surface
layers.
As the cutting speed is increased, the conditions promoting the built

up edge formation is also reduced due to a rise in temperature, which leads to
a corresponding reduction in the height of the micro irregularities
(roughness), which can be seen distinctly from Figure 5.15. Along with the
rise in temperature, the reduced friction and plastic deformation could also
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have caused the reduction in the surface roughness when the cutting speed is
increased.
3
2.5
2
1.5
0.5
0.05 0.102 0.143
Feed rate ( mm/rev)
Figure 5.14 Effect of Feed rate on Surface Roughness at Different

Cutting Speeds
3
2.5
2
1.5
depth of cut = 1 mm
0.5
22 33 54
Cutting speed ( m/min)
Figure 5.15 Effect of Cutting Speed on Surface Roughness at Different

Depths of Cut
The significance of the feed rate is higher over cutting speed and depth
of cut. This indicates the rubbing of the worn flank, and the associated change in
the surface roughness. This is clearly shown in Figure 5.16 (a-c), in which the
surface roughness tends to increase, as the flank wear increases at all levels of
the cutting speed. In addition, the low thermal conductivity of the nimonic C-263
alloy contributes to the higher generation of heat at the tool work contact zone.
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0.4 flank wear

4
0.35 surface roughness 3.5
0.3 3
0.25 2.5
0.2 2
0.15 1.5
0.1 1
0.051 0.102 0.143
Feed rate (mm/rev)
(a) Effect of feed rate on flank wear and surface roughness at cutting speed
of 22 m/min and depth of cut of 0.75 mm
0.4 3.9
0.35 flank wear
3.4
0.3 Surface roughness
0.25 2.9
0.2 2.4
0.15
0.1 1.9
0.05 1.4
0.051 0.102 0.143
Feed rate (mm/rev)
(b) Effect of feed rate on flank wear and surface roughness at cutting
speed of 33 m/min and depth of cut of 0.75 mm
0.4
0.35 3.2
0.3 2.7
0.25
0.2 2.2
0.15 flank wear
1.7
0.05 1.2
0.051 0.102 0.143
Feed rate (mm/rev)
(c) Effect of feed rate on flank wear and surface roughness at cutting
Figure 5.16 (a-c) Effect of Feed Rate on Flank Wear and Surface
Roughness at Different all Level of Cutting Speed for PVD
Coated Carbide Insert
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From Figure 5.17, it is seen that at a higher depth of cut, a

reduction in the surface roughness is observed. At a higher depth of cut, the
surface layer may get work-hardened, leading to a reduction in the surface
roughness. From the above, it is observed that the selection of the cutting
speed, feed rate and depth of cut for the tool/work combination is important to
achieve the desired surface finish.
3
2.5
2
1.5
1
0.5 feed rate = 0.102 mm/rev
0
0.5 0.75 1
Depth of cut ( mm)
Figure 5.17 Effect of Depth of Cut on Surface Roughness Different Feed
Rates
The SEM micrographs of the machined surface at different

cutting conditions are shown in Figure 5.18 (a-d). It indicates that the status of
the machined surface. At low level of cutting speed of 22 m/min and higher level of
feed rate of 0.143 mm/rev, the SEM images of machined surface indicates feed
marks, grooves, surface damage, smeared material, micro fracture, as evident in
Figure 5.18 (a). Figure 5.18 (b) shows the SEM micrograph of the machined
surface at middle level of cutting speed and higher level of feed rate, the
visible feed marks and microscratches is seen, while a smooth surface finish
is observed at higher level of cutting speed and low level of depth of cut. At
lower cutting speed, there could be adherence of chip onto the tool surface
due to pressure weld between the tool and the chip which may randomly
pluck and scratch the machined surface. In addition, the possibility of
periodical removal of aggregates of the tool particles and the corresponding
change in the tool geometry could have resulted the rough surface as seen
from the micrographs given in Figure 5.18 (a-d).
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(a) SEM Micrographs of machined (b)SEM Micrographs of machined

surface at cutting speed of surface at cutting speed of 33
22m/min, feed rate of 0.143 m/min, feed rate of 0.143 mm/rev
mm/rev and depth of cut of 1 mm and depth of cut of 1 mm
(c) SEM Micrographs of machined (d) SEM Micrographs of

surface at cutting speed of 33 machined surface at cutting speed
m/min, feed rate of 0.102 mm/rev of 54 m/min, feed rate of 0.051
and depth of cut of 1 mm mm/rev and depth of cut of 1 mm
Figure 5.18 (a-d) SEM Micrographs of Machined Surface at Different

Cutting Conditions using PVD Coated Carbide Insert
5.3.4 Effect of Machining Parameters on the Flank Wear Using PVD

Coated Carbide Insert.
the flank wear at different depths of cut, which can help in the prediction of
the flank wear at any zone of the experimental domain.
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(a) Flank wear at 0.50 mm depth of cut
(b) Flank wear at 0.75 mm depth of cut
(c) Flank wear at 1 mm depth of cut
Figure 5.19 (a-c) Flank Wear Contours in Velocity- Feed Plane at

Different Depths of Cut for PVD Coated Carbide Insert
189
flank wear. These surface plots are drawn, using the developed RSM model
middle level. It is clear from these figures that the least flank wear occured at
middle level cutting speed and at low level of feed rate and depth of cut;
however, it increases with increase in feed rate and depth of cut. It is found
that the flank wear varies between the range of 0.19-0.38 mm in machining
nimonic C-263 alloy under different level of machining parameters using the
PVD coated carbide insert.
(a) 3D response surface plots for the flank wear at 0.75 mm depth of cut
(b) 3D response surface plots for the flank wearat 0.102 mm/rev feed rate
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(c) 3D response surface plots for the flank wear at 33 m/min cutting
speed
Figure 5.20 (a-c) 3D Response Surface Plots for the Flank Wear using
PVD Coated Carbide Insert
The flank wear was high at higher cutting speed and feed rates as
seen from the Figure 5.21. The flank wear is high at high level cutting speed
and depth of cut while the flank wear is low comparatively at middle level of
cutting speed and low level of depth of cut as observed in Figure 5.22.
0.4
0.35
0.3
0.25
0.2 Cutting speed = 33 m/min
0.15
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.21 Effect of Feed rate on Flank Wear at Different Cutting

Speeds
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0.45
0.4
0.35
0.3
0.25
0.2 depth of cut = 0.50 mm
depth of cut = 1 mm
0.1
22 33 54
Figure 5.22 Effect of Cutting Speed on Flank Wear at Different Depths

of Cut
At increasing cutting speed and feed rate, the concentration of high

temperature very close to the cutting edge has caused notching and increase in
nose and flank wear.The flank wear is progressively increased with the
increase in depth of cut for the various level of feed rate as seen in
Figure 5.23.
0.5
0.4
0.3

0.1
0.5 0.75 1
Depth of cut (mm)
Figure 5.23 Effect of Depth of Cut on Flank Wear at Different Feed Rates
During machining, the wear phenomena occur on the tool that

reduces its cutting efficiency which mostly cause an increase in mechanical
and thermal stresses as well as deterioration in the machining quality. While
machining nimonic C-263 alloy, its thermal fatigue resistance which resulted
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due to the presence of finely dispersed second phase, develops a number of

wear mechanisms. While turning using PVD coated carbide inserts, main
wear mechanisms are plastic deformation, chipping, adhesion and notch wear.
It is important to understand and identify which is the most prominent, for
adopting suitable machining strategy.
Figure 5.24 (a-f) shows the SEM images of the flank wear land of
PVD coated carbide insert (S grade) at different cutting conditions. From the
SEM micrographs Figure 5.24 (a-c), the initiation of wear marks can be seen
at the flank of the insert, which can be attributed to the abrasive action of
micro hard carbide precipitates present in the work material and thus the main
wear mechanism at the lower cutting speed of 22m/min. However, as tool
wear progresses, the contact between tool flank and machined work surface
increases, which leads to increase in wear and also the possibility of low order
edge chipping as seen from Figure 5.24 (c).
At higher cutting speed, as observed from the SEM micrograph

shown in Figure 5.24 (d), severe abrasion marks and micro tool chipping are
visible. It is seen from the SEM images shown in Figure 5.24 (e & f) that the
higher chipping of cutting edge and intense plastic deformation could have
resulted due to higher contact pressure and temperature that were induced due
to higher cutting speed. It can be concluded that mainly the flank wear
dictates the life of the cutting insert (HMT 2001) and the main tool wear
mechanisms while turning nimonic C-263 alloy using carbide insert are
abrasion, adhesion, micro chipping and plastic deformation. Further the
magnitude of wear depends on the cutting speed and wear condition of cutting
insert.
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(a) V-22m/min, S-0.05mm/rev, ap = 0.50 mm (d) V-54m/min, S-0.143mm/rev, ap = 0.50 mm

(b) V-22m/min, S-0.102mm/rev, ap = 0.75 mm (e) V-54m/min, S-0.143mm/rev, ap = 0.75 mm
(c) V-22m/min, S-0.143mm/rev, ap = 1 mm (f) V-54m/min, S-0.143mm/rev, ap = 1 mm
Figure 5.24 (a-f) SEM Micrographs of Worn out Cutting Edge at

Different Cutting Conditions for PVD Coated Carbide
Insert
194
5.4 COMPARISON OF EXPERIMENTAL RESULTS WITH

RSM AND ANN MODEL VALUES FOR PVD COATED
CARBIDE INSERT
The comparison between the experimental results , predicted

values by Response Surface Methodology and predicted by Artificial Neural
Network model were evaluated for the responses such as the cutting force,
temperature at tool tip, surface roughness and flank wear in machining
nimonic C-263 alloy using PVD coated carbide insert.
The experimental results and RSM modelled values for the cutting
force, temperature at tool tip, surface roughness and flank wear in machining
nimonic C-263 alloy using PVD coated carbide insert is shown in Table 5.1.
From the Table 5.1, a good aggrement is obtained between the actual
experimental results and predicted values based on RSM model, indicating
the effectiveness of prediction of cutting force, temperature at tool tip, surface
roughness and flank wear with 95% confidence levels during the machining
of the nimonic C-263 alloy using PVD coated carbide insert.
The percentage error among the experimental results, predictive

values by RSM and ANN models is presented in the Table 5.2. The average
percentage error for the responses such as the cutting force, temperature at
tool tip, surface roughness and flank wear between the experimental results
and RSM model values were 4.31%, 3.50 %, 4.37%, and 1.28% respectively.
The average percentage error for the responses such as the cutting
force, temperature at tool tip, surface roughness and flank wear between the
experimental results and ANN model values were 2.72%, 1.19%, 1.76%, and
4.17% respectively.
195
Table 5.1 Experimental and Model Results for PVD Coated Carbide
Insert
Expt Experimental Values RSM Values

No Fz Ra VB Fz Ra VB
(N) C) (µm) (mm) (N) C) (µm) (mm)
1 340 300 1.750 0.225 381 296 1.73 0.23
2 420 320 1.651 0.250 399 319 1.64 0.25
3 470 340 1.452 0.270 431 341 1.41 0.273
4 450 385 2.250 0.260 453 390 2.32 0.25
5 425 415 2.123 0.275 462 413 2.23 0.27
6 450 440 1.932 0.295 486 434 1.99 0.31
7 542 465 2.750 0.310 535 462 2.87 0.29
8 560 485 2.935 0.320 537 485 2.77 0.32
9 585 500 2.652 0.330 554 505 2.53 0.35
10 410 375 1.550 0.190 386 390 1.66 0.20
11 385 420 1.530 0.220 393 415 1.59 0.22
12 410 435 1.402 0.250 416 438. 1.37 0.24
13 510 475 2.730 0.200 439 474 2.22 0.22
14 415 510 2.100 0.245 438 498. 2.13 0.24
15 445 530 1.853 0.265 452 521 1.90 0.27
16 475 545 2.530 0.230 505 537 2.73 0.25
17 510 555 2.752 0.270 498 561 2.64 0.28
18 475 575 2.203 0.345 505 583 2.41 0.31
19 395 465 1.490 0.350 403 457 1.46 0.32
20 386 490 1.352 0.310 392 485 1.39 0.33
21 385 510 1.252 0.330 395 511 1.18 0.35
22 420 520 1.840 0.300 420 520. 1.93 0.32
23 435 540 1.753 0.365 401 547 1.86 0.34
24 400 560 1.652 0.380 396 573 1.64 0.36
25 442 565 2.420 0.365 458 566 2.38 0.35
26 420 585 2.350 0.350 432 593 2.30 0.37
27 438 600 2.120 0.385 420 619 2.08 0.40
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Table 5.2 Percentage Error Between the Experimental, RSM and ANN
with Respect to PVD Coated Carbide Insert
% error % error
Expt Experimental Vs RSM Experimental Vs ANN
(N) C) (µm) (mm) (N C) (µm) (mm)
1 12 1.14 2.22 1.33 4.76 4.33 0.57 4.54
2 5 0.66 0 0.31 0.95 0 0.54 0
3 8 2.89 1.1 0.29 0.42 0.29 0.13 0
4 0.66 3.11 3.84 1.29 7.77 0.25 0.88 3
5 8.70 5 1.85 0.48 0.47 1.92 0.14 1
6 8 3 5 1.36 1.77 0.22 5.18 1
7 1.29 4.36 6 0.64 0.18 0 0.36 6
8 4.10 5.62 0 0 1.25 0.20 2.55 0
9 5.29 4.60 6 1 2.39 0 1.20 0
10 5 7 5 7 3.65 0.26 0 14
11 2 3.92 0 1.1 1.03 0 1.96 0
12 1.46 2.28 4 0.68 1.21 7.35 0.71 4
13 13 0.21 10 0.21 0.39 4.42 2.56 10
14 5 1.42 2.0 2.35 0.48 0 0.47 6.12
15 1.57 2.53 1.88 1.69 0.89 0.18 0.16 5
16 6 7 8 1.46 4 0.18 1.97 4
17 2.35 4 3.70 1 0.98 1.80 3.70 3
18 6.31 9 10 1.39 14.73 0.52 1.67 5.88
19 2 2 8 1.72 3.03 2.58 2.01 5.71
20 1.81 2.81 6 1 2.84 0 2.22 0
21 2.59 5 6 0.19 2.07 0 1.44 0
22 0 4.80 6.66 0 0.23 4.23 0.54 3
23 7.8 6 6.84 1.29 2.06 0.55 2.11 9.58
24 1 0.72 5.26 2.32 1.25 0 4.35 10
25 3.61 1.65 4.10 0.17 10 0.35 0 6
26 2.85 2.12 5.71 1.36 1.19 1.36 0.42 2.85
27 4.10 1.88 3.89 3.10 3.65 1.16 9.90 9
Figures 5.25 (a-b) shows the percentage error between

experimental and predicted value with RSM model and ANN model
respectively. These results indicate that the predicticted responses such as
197
cutting force, temperature at tool tip, surface roughness and flank wear with
ANN model seems to have better prediction potential in machining of
nimonic C-263 alloy using PVD coated carbide insert. However, the ANN
model consumes lesser computational time besides giving higher accuracy
(Ranganathan et 2010). The models designed by ANN and RSM models would
be helpful to predict these responses during the machining of the nimonic C-263
alloy using PVD coated carbide insert.
14
12 Fz
10
Ra VB
8
6
4
2
0
1 2 3 4 5 6 7 8 9 1011 12 13 1415161718 192021 22 2324 252627
Experiment Number
(a) Percentage error between the experimental results and RSM

predicted Values for PVD coated carbide insert
14
12 Fz
Ra VB
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Experiment Number
(b) Percentage error between the experimental results and ANN

predicted Values for PVD coated carbide insert
Figure 5.25 (a-b) Percentage Error among the Experimental results,

RSM and ANN predicted Values for PVD coated carbide
insert
198
5.5 CONFIRMATION EXPERIMENT FOR OPTIMAL

SOLUTION USING PVD COATED CARBIDE INSERT
The confirmation experiments were performed for the optimal

solutions obtained from the Response Surface Method based desirability
approach in machining the nimonic C-263 alloy using PVD coated carbide
insert. The confirmation experiments were performed in the following range
of the input parameters: cutting speed-23 m/min, feed rate-0.05 mm/rev and
depth of cut 0.50 mm. The plan for the confirmation experiment , the values
of Fz, , Ra and VB, obtained by the confirmation experiment, and predicted
through the optimization approach are given in Table 5.3. The result indicates
that the predicted values are reasonably closer to the experimental results.
Table 5.3 Plan of the Confirmation Experiments and Results for PVD
Fz (N) (°C) Ra ( m) VB(mm)

Sol. V S ap Predict ed Experimental Predict Experimental Experi-
Predicted
No. (m/min) (mm/rev) (mm) Predicted Experimental valuses valuses ed valuses mental
valuses valuses valuses
valuses
1 23 0.05 0.50 381 385 307 315 1.71 1.80 0.22 0.20
2 23 0.05 0.50 381 378 307 320 1.71 165 0.22 0.21
3 23 0.05 0.50 381 375 307 310 1.71 170 0.22 0.20
5.6 FINITE ELEMENT MODELLING
The Finite Element Model has been carried out to predict the responses such
as the cutting force, temperature at tool tip, effective stress and effective strain
through simulation. The simulated model of the cutting force, temperature at
tool tip is compared with the experimental results.
199
5.6.1 Cutting Force Simulation and Validation
The coded values of machining parameters, actual setting values,

FEM predicted outputs and experimental results are given in the Table 5.4.
The comparison of modelled and experimental values for the generation of
cutting force is illustrated in Figure 5.26.
From the Figure 5.26, it can be seen that the predicted values are
closer to the experimental values. Further, from the Figure 5.27, the
percentage error computed between the experimental and FEM predicted
values ranges almost within 6%, which clearly indicates the reasonable
correlation between the FEM model and experiment. Thus the simulated
FEM results can be used effectively for predicting the cutting force while
turning nimonic C-263 alloy.
800
700
600
500
400
300
200 Fz-Experimental value
100 Fz-Predicted thro FEM model
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure 5.26 Comparison of Measured and Simulated Cutting Force
14
12
10
8
6
4
2
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure.5.27 Percentage Error Between Experimental and Predicted
Values for Cutting Force
200
Table 5.4 Experimental Conditions and Results
Sl. V S ap Experimental FEM model predicted

No. (m/min) (mm/rev) (mm) output output
Fz Fz Stress Strain
(N) (°C) (N) (°C) (MPa) (mm/mm)
1 22 0.05 0.50 340 300 398 325 375 3.100
2 22 0.05 0.75 420 320 425 340 405 3.250
3 22 0.05 1 470 340 455 365 435 3.750
4 22 0.102 0.50 400 385 435 370 500 4.050
5 22 0.102 0.75 435 415 455 390 520 4.225
6 22 0.102 1 450 440 465 465 575 4.350
7 22 0.143 0.50 542 465 580 490 620 4.650
8 22 0.143 0.75 560 485 585 510 630 4.750
9 22 0.143 1 585 500 662 540 645 4.925
10 33 0.05 0.50 320 375 365 410 400 3.575
11 33 0.05 0.75 385 420 410 430 425 3.725
12 33 0.05 1 410 435 425 440 480 3.825
13 33 0.102 0.50 425 475 430 510 600 4.700
14 33 0.102 0.75 415 510 425 545 630 4.925
15 33 0.102 1 445 530 460 550 690 5.200
16 33 0.143 0.50 475 545 495 585 700 5.420
17 33 0.143 0.75 510 555 520 570 720 5.350
18 33 0.143 1 475 575 495 610 730 5.575
19 54 0.05 0.50 395 465 410 485 590 4.750
20 54 0.05 0.75 386 490 415 510 610 4.600
21 54 0.05 1 385 510 395 535 650 4.800
22 54 0.102 0.50 420 520 415 545 690 5.100
23 54 0.102 0.75 440 540 445 555 720 5.400
24 54 0.102 1 400 560 391 575 750 5.725
25 54 0.143 0.50 442 565 455 590 785 6.125
26 54 0.143 0.75 420 585 435 620 790 6.250
27 54 0.143 1 438 600 450 610 810 6.550
201
Figure 5.28 (a-f) illustrates few output of the cutting force

generated during FEM simulation processes at different cutting conditions.
The cutting forces fluctuated in the transient simulations and remained steady
above 600 steps. From the illustrations, it is seen that cutting force ranges
between 390 N to 672 N depending upon the cutting conditions. From the
Figure 5.28 (a to f), an increase in cutting force could be seen with increase in
feed rate. But with higher depth of cut (1mm), and a steep increase in cutting
force to an extent of 672 N is observed with increase in feed rate (Figure 5.28
(c & d)), which could be attributed to the generation of higher order chip load
at higher combination of feed and depth of cut. This large increase in cutting
force from 478 N to 672 N corresponding to the feed rates of 0.102mm/rev to
0.143 mm/rev, identifies the feed rate of 0.102mm/rev as critical feed rate for
turning nimonic C-263 alloy. However the increase in cutting speed, reduces
the cutting force. This could be attributed to the thermal softening of material
at higher cutting speed.
(a) Simulated cutting force at cutting speed of 22m/min, feed rate of

0.05mm/rev and depth of cut of 0.50mm
202
(b) Simulated cutting force at cutting speed of 22m/min, feed rate of

0.102mm/rev and depth of cut of 0.50mm
(c) Simulated cutting force at cutting speed of 22m/min, feed rate of

0.102mm/rev and depth of cut of 1 mm
(d) Simulated cutting force at cutting speed of 22m/min, feed rate of 0.143
mm/rev and depth of cut of 1 mm
203
(e) Simulated cutting force at cutting speed of 33m/min, feed rate of 0.102
mm/rev and depth of cut of 1 mm
(f) Simulated cutting force at cutting speed of 54 m/min, feed rate of

0.143 mm/rev and depth of cut of 1 mm
Figure 5.28 (a-f) Generated Cutting force During FEM Simulations at
Different Cutting Conditions
5.6.2 FEM Simulation and Experimental Validation of Temperature

at Tool Tip
The generation of heat also affects the subsurface of the machined

surface which is more detrimental and of more concern in the case aerospace
materials. Therefore, it is required to investigate the generation of cutting
temperature while machining. The predicted temperature at tool tip using
204
FEM model and experimentally measured temperature at the tool tip are
compared in Figure 5.29. The percentage error between the experimental and
predicted values through FEM model ranges within 8% percentage as shown
in the Figure 5.30. From the Figures 5.29 and 5.30, it can be seen that the
predicted values are reasonable closer to the experimental values.
800
700
600
500
400
300
200 Temp-Experimental value
Temp-Predicted thro FEM model
100
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure 5.29 Comparison of Measured and Simulated Temperature at Tool Tip
Figure 5.30 Percentage Errors between the Experimental and the

Predicted Values for Temperature at Tool Tip
The temperature distribution at the tool tip at different cutting

conditions is illustrated in Figure 5.31 (a-c). The temperature at the tip of the
tool varies based on the level of the machining parameters. It is observed that
205
the temperature generation at the tool tip increases with increasing the cutting
speed, feed rate and depth of cut. From the illustrations, the highest cutting
temperature occurred at the end of tool tip to an extent of 610°C at a
combination of cutting speed 54m/min, feed rate 0.143mm/rev and depth of
cut of 1 mm. However with lower cutting conditions a temperature around
370°C near the tool tip is observed. From the Figure 5.31 (a-c), it can be seen
that the highest tool face temperature could be located at the tip of cutting
edge which clearly shows the basic machining characteristic of the low
thermal conductivity Nickel based nimonic C-263 material, which agrees with
the reported results by (Smart et al 1975).
Apart from the low thermal conductivity, the specific cutting

strength is high in the case of super alloys due to the presence of '
precipitates and complex metallic carbides at the grain boundaries inhibit the
deformation causing the generation of higher temperature at the shear zone.
Also, a high temperature concentration could be seen at the tool tip unlike
machining of steel, where the higher temperature normally results at a finite
distance from the tool tip, indicating the basic material characteristics of
nimonic C-263 super alloy.
(a) Simulated Temperature at cutting speed of 22 m/min, feed rate of

0.102 mm/rev and depth of cut of 0.50 mm
206
(b) Simulated Temperature at cutting speed of 33 m/min, feed rate of

0.102 mm/rev and depth of cut of 0.75 mm
(c) Simulated Temperature at cutting speed of 54 m/min, feed rate of

0.143 mm/rev and depth of cut of 1 mm
Figure 5.31 (a-c) FEM Simulated Temperature Distributions at

Different Cutting Conditions for PVD Coated Carbide
Insert
207
5.6.3 FEM Simulation of Effective of Stress and Strain
During machining the work material undergoes shear deformation

when the cutting edge indents on the work piece. The variation of magnitude
depends upon the cutting conditions. Creep-resistant alloys like nimonic
C-263 are metallurgically designed to retain high strength at elevated
temperatures and therefore, the stresses in the flow-zone are very high.
Figures 5.32 and 5.33 illustrate the distribution of effective stress and strain
using FEM simulation at different machining conditions while turning
nimonic C-263 alloy using coated carbide tool.
From Figure 5.32 (a-c), it is observed that the magnitude of the

effective stress increase with the increase in feed rate and cutting speed. A
maximum stress value of 720 MPa is observed at a cutting speed of 54m/min.
Larger deformation is more evident at the tool work contact area where the
chip curls more. As the cutting speed is increased from 22m/min to 54m/min,
the deformation will be more thus simulating larger strain to an extent of up to
5.4 mm/mm, which is shown in Figure 5.33 (a-c).
The predicted values of effective stress and strain using FEM

simulation for different machining parameters on machining nimonic C-263
alloy is shown in the Figures 5.34 and 5.35. It is also observed from the
Figure 5.34, that the effective stress increases with the increasing the level of
cutting speed, feed rate and depth of cut. This may be attributed due to the
friction between the tool-work piece interfaces and thus increases the rate of
heat generation. From Figure 5.35, it is observed that the high level of
machining parameters have induced grater effective strain. It is due to high
level of machining parameters and low thermal conductivity of nimonic C-
263 alloy causes more heat generation and work hardening, creating greater
thermo-mechanical load on to the work piece.
208
(a) Effective stress distributions at cutting speed of 22 m/min, feed rate of 0.102
mm/rev and depth of cut of 0.75 mm
(b) Effective stress distributions at cutting speed of 33 m/min, feed rate of 0.102
(c) Effective stress distributions at cutting speed of 54 m/min, feed rate of 0.102
Figure 5.32 (a-c) Effective Stress Distributions at Different Cutting

Conditions for PVD Coated Carbide Insert
209
(a) Effective strain distributions at cutting speed of 22 m/min, feed rate of 0.102
(b) Effective strain distributions at cutting speed of 33 m/min, feed rate of 0.102
(c) Effective strain distributions at cutting speed of 54 m/min, feed rate of 0.102
Figure 5.33 (a-c) Effective Strain Distributions at Different Cutting

Conditions PVD Coated Carbide Insert
210
1000
800
600
400
200
Effective stress (MPa)
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure 5.34 FEM Simulation of Effective Stress
30
25
20
15
10
Effective strain (mm/mm)
5
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Experiment Number
Figure 5.35 FEM Simulation of Effective Strain
5.7 ON-LINE TOOL WEAR MONITORING
In this research work, an attempt has also been made to monitor the
status of the PVD coated carbide insert by acquiring AE signal while turning
nimonic C-263 alloy at different cutting speed and feed rate, at constant depth
of cut.
5.7.1 Monitoring of Acoustic Emission for PVD Coated Carbide

Insert
The physical process of removing metal chips from a work piece

with a sharp cutting edge requires large plastic deformation of the metal at a
very high strain rate followed by fracture process. These processes are well
211
known sources of AE, and monitoring the AE signal from the cutting zone
can provide useful information concerning the status of the cutting edges as
well as the process itself. Thus the status of the cutting tool to machining
environment was assessed by integrating suitable AE transducer near cutting
edge and monitoring online the acoustic emission signal emitted from the
cutting zone. The acoustic emission from the cutting process consists of
continuous and transient signals, each corresponding to the different events
like, tool wear, and chipping. While sensing the AE signals, the depth of cut
was kept constant at 0.75mm. Typical FFT of the AE signals generated at
different tool wear conditions and at different cutting conditions are shown in
Figure 5.36 (a-f).
When turning the nimonic C-263 alloy at cutting speeds of 22 and

33 m/min with feed rates of 0.102 and 0.143 mm/rev, the cutting edge
undergoes running in wear thus responding with sharp and lower acoustic
emission frequency around 40 kHz and 60 kHz as seen from the Figure 5.36
(a-d) by the presence of dominant peaks. Also when the tool is sharp the chip
breakage will be better thus producing a smaller magnitude signal with a very
narrow frequency range. This is indicated by the occurrence of higher
amplitude frequency components in the lower range. When the tool fracture
occurs, most of the tool edge is broken to generate AE signal produce, and
correspondingly very large and very wide frequency components are seen
even beyond frequency of 350 kHz, together with the low frequency
components as seen in the Figures 5.36 (a-d).
Typical FFT of the AE signals generated at different tool conditions

when turning nimonic C-263 alloy at higher cutting speed of 54 m/min, with
respect to the feed rates of 0.102 mm/rev and 0.143 mm/rev are shown in
Figure 5.36 (e-f). At higher combination of cutting speed and feed rate, the
strain rate is high and the resisting cross section under cutting edge due to
212
higher feed rate also more. Due to this, the energy of the signal produced is
high as seen from all the Figures. 5.36 (e to f), i.e. the signal is spread in
wider range, than at lower combinations of cutting conditions. As the tool
flank wear increases, an increase in the amplitude of the signal seen. Apart
from the occurrence of low frequency components of 50 kHz as seen from the
lower cutting conditions, the dominant peaks are also seen at frequencies of
75 kHz, 125 kHz, 250 kHz and 350 kHz, possibly due to higher order
stressing of the material at higher cutting speed indicating worn out status of
the tool.
The presence of dominant peaks around 50 kHz, irrespective of tool

condition and cutting conditions can be attributed to the response of the
nimonic C-263 alloy. From the above discussion, it can be concluded that
generation of AE signal acquired at different tool condition and the amplitude
and frequency of AE processed through FFT clearly indicates the status of cutting
insert while turning nimonic C-263 super alloy using PVD coated carbide insert.
(a) Fast Fourier Transform of Acoustic Emission at cutting speed of 22

m/min, feed rate of 0.102 mm/rev and depth of cut of 0.75 mm
213
(b) Fast Fourier Transform of Acoustic Emission at cutting speed of 22

m/min, feed rate of 0.143 mm/rev and depth of cut of 0.75 mm,
(c) Fast Fourier Transform of Acoustic Emission at cutting speed of 33

m/min, feed rate of 0.102 mm/rev and depth of cut 0.75 m
(d) Fast Fourier Transform of Acoustic Emission cutting speed of V-33 m/min,
feed rate of 0.143 mm/rev and depth of cut of 0.75 mm
214
(e) Fast Fourier Transform of Acoustic Emission at cutting speed of 54

(f) Fast Fourier Transform of Acoustic Emission at cutting speed of 54

Figure 5.36 (a-f) Fast Fourier Transform (FFT) of Acoustic Emission
(AE) Signals at Different Cutting Conditions for PVD

RESPONSES IN TURNING NIMONIC C-263 ALLOY USING
WHISKER REINFORCED CERAMIC INSERT.

evaluated and analysed in turning nimonic C-263 alloy using whisker
reinforced ceramic insert.
215
5.8.1 Effect of Machining Parameters on the Cutting Force
the cutting force at different depths of cut, the contour can help in the
prediction of the cutting force at any zone of the experimental domain.
Figure 5.37 (c) Cutting forces at 1 mm depth of cut

Different Depths of Cut for Whisker Reonforced Ceramic
Insert
216
middle level. It is observed from these Figures 5.38 (a-c) that the lowest
cutting force is obtained at a higher level of cutting speed and lower level of
feed rate and depth of cut. It is also found that the cutting force (Fz) varies
between the range 410-680N of in machining nimonic C-263 alloy under
different levels of machining parameters using whisker reinforced ceramic
insert.
(a) 3D response surface plots for cutting force at depth of cut of 0.75 mm
(b) 3D response surface plots for cutting force at feed rate of 0.102
mm/rev
217
(c) 3D Response Surface Plots for Cutting Force at Cutting Speed of 190
m/min
Figure 5.38 (a-c) 3D Response Surface Plots for Cutting Force using
Whisker Reinforced Ceramic Insert
The influence of the machining parameters on the cutting force is

illustrated in Figures 5.39 - 5.41. From Figure 5.39, it is observed that the
cutting force tends to increase when the feed rate increases, for all levels of
cutting speed. Further it is observed that, the maximum cutting force of 625 N
is generated at a higher level feed rate of 0.143 mm/rev and a lower level
cutting speed of 125 m/min. The magnitude of the cutting force component is
reduced when the cutting speed is increased.
650
600
550
500
450
400
250
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.39 Effect of feed rate on cutting force at different cutting speeds
218
From Figure 5.40, it is observed that the maximum magnitude of

the cutting force component is 630 N, at a lower level cutting speed and a
higher level of depth of cut .The magnitude of the cutting force tend to
increase with lower cutting speed for all the levels of the depths of cut.
Further, it is observed that the magnitude of the cutting forces was high at a
low cutting speed; this is probably due to the high coefficient of friction
between the tool and the work material, compared to that at a higher cutting
speed. The generation of heat is greater at higher cutting speed causing
softening of the material thereby decreasing the cutting force.
650
600
550
500
450
250
125 190 250
Figure 5.40 Effect of Cutting Speed on Cutting Force at Different Depths of

cut
Figure 5.41 shows that the cutting force tends to increase, when the
feed rate and depth of cut increases. The maximum cutting force of 620 N is
observed at high level of depth of cut and feed rate.
650
600
550
500
450
250
0.5 0.75 1
Depth of cut (mm)
Figure 5.41 Effect of Depth of Cut on Cutting Force at Different Feed

Rates
219
At a higher feed rate, the flank wear increases causing increase in

cutting force, which are evidently seen from Figure 5.42. The increase in the
flank wear at a higher feed rate is due to the damage of the cutting edge,
creating the abrasion between the tool edge and work piece surface there by
the generation of the cutting force is high.
600
0.35
550
0.25
500
450 0.15
Cutting force
flank wear
400 0.05
0.051 0.102 0.143
Feed rate (mm/rev)
cutting speed of 190 m/min and depth of cut of 0.75 mm
5.8.2 Effect of Machining Parameters on the Temperature Rise at

Tool Tip
Figure 5.43 (a-c) illustrates the contour maps in the feature plane
for temperature at tool tip at different depths of cut. These response contours
can help in the prediction of the temperature rise at tool tip at any zone of the
220
(c) Temperature at tool tip at 1 mm depth
Figure 5.43 (a-c) Temperature at Tool Tip Contours in Velocity- Feed

Plane at Different Depths of Cut for Whisker Reinforced
Ceramic Insert
221
temperature rise at tool tip. These surface plots are drawn, using the
developed RSM model by varying the two different parameters and keeping
the third parameter at the middle level. It is clear from this Figure 5.44 (a-c)
that the temperature rise at tool tip is high at higher cutting speed and feed
rate. The temperature at the tool tip is reduced when the level of depth of cut
and feed rate is reduced. It is found that the temperature at tool tip varies
between the range of 365-720°C in machining nimonic C-263 alloy under
different levels of machining parameters using the whisker reinforced ceramic
insert.
(a) 3D response surface plots for temperature at tool tip at depth of cut
of 0.75 mm
(b) 3D response surface plots for temperature at tool tip at cutting speed
of 190 m/min
222
(c) 3D response surface plots for temperature at tool tip at feed rate of
0.102 mm/rev
Figure 5.44 (a-c) 3D response surface plots for temperature at tool tip
using Whisker Reinforced Ceramic Insert
Further the effect of machining parameters on temperature rise at

the tool tip during machining nimonic C-263 alloy are shown in the
Figures 5.45 - 5.47. From Figure 5.45, it is observed that the cutting
temperature tends to increase when the feed rate and cutting speed increases.
A maximum temperature of 676 C is generated at a higher level of feed rate
and cutting speed. The results indicate that the increase in feed rate results in
the increase of the temperature at tool tip. With the increase in the cutting
speed and the feed rate, the concentration of higher temperature very close to
the cutting edge causes the notching and flank wear.
700
625
550
475
250
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.45 Effect of Feed Rate on Temperature at Tool Tip at Different

Cutting Speed
223
From Figure 5.46, it is observed that the temperature at tool tip is

648 C at a higher level of cutting speed and depth of cut .The temperature at
tool tip tends to increase when the level of cutting speed and depth of cut
increases.
700
625
550
475
250
125 190 250

From Figure 5.47, it is observed that the temperature at tool tip

tends to increase, when the level of the feed rate and depth of cut increases. A
maximum of temperature of 660 C is observed at the tool tip at high level of
depth of cut and feed rate. Further, it is observed that the temperature at tool
tip increases and with the increasing level of cutting speed, feed rate and
depth of cut.
700
625
550
475
250
0.5 0.75 1
Depth of cut (mm)

Different Feed Rate
224
5.8.3 Effect of Machining Parameters on the Surface Roughness
surface roughness at different depths of cut, the surface roughness at any zone
of the experimental domain can be predicted.

225
(c) Surface roughness at 1 mm depth of
Figure 5.48 (a-c) Surface Roughness Contours in Velocity- Feed Plane at

Different Depths of Cut for Whisker Reinforced Ceramic
Insert
Figures 5.49 (a-c) illustrate the 3D response surface plots for

model by varying the two different parameters, and keeping the third
parameter at the middle level. It is clear from these figures, that the lowest
surface roughness is obtained at a high level of cutting speed and depth of cut
and low level of feed rate.
(a) 3D response surface plots for surface roughness at depth of cut of

0.75 mm
226
(b) 3D response surface plots for surface roughness at cutting speed of

190 m/min
(c) 3D response surface plots for surface roughness at feed rate of 0.102
mm/rev
Figure 5.49 (a-c) 3D Response Surface Plots for Surface Roughness using
Figure 5.50 shows the effect of the feed rate at different cutting
speeds on the surface roughness. From the illustration, it is seen that an
increase in the feed rate results in an increase surface roughness. However,
the surface roughness is reduced with the increase in the cutting speed. At a
higher feed rate the height of the ridges (roughness) is increased, thus
contributing to a higher surface roughness.
227

1
0.05 0.102 0.143
Feed rate ( mm/rev)
Figure 5.50 Effect of Feed Rate on Surface Roughness at Different

Cutting Speeds
Figure 5.51 shows the effect of the feed rate and the depth of cut on
the surface roughness. From the illustration, it is seen that the increase in the
feed rate increases the surface roughness, whereas the best surface roughness
is observed at a high level of the depth of cut and a low level of the feed rate.
It is seen that at a higher depth of cut, a reduction in the surface roughness is
observed. This is because, at a higher depth of cut, the surface layer may get
work hardened, thus leading to a reduction in the surface roughness.
2
1
0.5 0.75 1
Depth of cut ( mm)
Figure 5.51 Effect of Depth of Cut on Surface Roughness at Different

Feed Rates
228
Figure 5.52 show that the increase in the depth of cut and cutting
speed reduces the surface roughness. The surface roughness observed for the
combination of depth of cut and cutting speed is lower than the surface
roughness observed for the combination of low level of depth of cut and
cutting speed. It can be realized that the high level of depth of cut and cutting
speed gives the best possible cut.

depth of cut = 1 mm
1
125 190 250

Depths of Cut
The significance of the feed rate is higher followed by the cutting speed
and depth of cut on surface roughness. Further, it is noted that the rubbing of the
wornout tool on the work piece associates the change in the surface roughness.
This is clearly shown in Figure 5.53 (a-c), in which the surface roughness tends to
increase, as the flank wear increases at all levels of the cutting speed. In
addition, the low thermal conductivity of the nimonic C-263 alloy contributes to
the accumulation of heat at the tool-work contact zone.
229
0.4 4
0.35
0.3 3.5
0.25
3
0.2
0.15 flank wear
2.5
Surface roughness
0.1
0.05 2
0.051 0.102 0.143
Feed rate (mm/rev)
(a) Effect of feed rate on flank wear and surface roughness at cutting
0.4 4
0.35
0.3 3.5
0.25
3
0.2
0.15 2.5
0.1 Cutting force
Surface roughness
0.05 2
0.051 0.102 0.143
Feed rate (mm/rev)
230
0.5 4
0.45
0.4 3.5
0.35
0.3 3
0.25 2.5
0.2
0.15 2
flank wear
0.05 1.5
0.051 0.102 0.143
Feed rate (mm/rev)
(c) Effect of feed rate on flank wear and surface roughness at 250 m/min
cutting speed and depth of cut of 0.75 mm
Roughness at all level of Cutting Speed for Whisker
Reinforced Ceramic Insert
Figure 5.54 (a-d) shows the SEM micrographs of the machined

surface under different cutting conditions. It indicates the status of the
machined surface, in terms of the smeared surface, feed marks, chip particles,
rough surface, smooth surface etc. These surface status are generally
attributed to the generation of forces and temperatures at the cutting zone, and
also to the deformation on the flank face, and adherence of the work piece
material.
231
(a) SEM Micrograph of (b) SEM Micrograph of

machined surface at cutting machined surface at cutting
speed of 125m/min, feed rate of speed of 190m/min, feed rate of
0.143 mm/rev and depth of cut 0.143 mm/rev and depth of cut
of 1 mm of 1 mm
(c) SEM Micrograph of (d) SEM Micrograph of

machined surface at cutting machined surface at cutting
speed of 250m/min, feed rate speed of 250m/min, feed rate of
of 0.102 mm/rev and depth of 0.0.051 mm/rev and depth of cut
cut of 1 mm of 1 mm

Cutting Conditions using Whisker Reinforced Ceramic
Insert
232
At a lower cutting speed there could be an adherence of the chip

onto the tool surface, due to the pressure weld between the tool and the chip,
which may randomly pluck and scratch the machined surface. Further, the
possible periodical removal of aggregates of the tool particles and the
corresponding acceleration of the wear and the associated impairing of the
machined surface could have resulted, as observed from the micrographs. The
increase in temperature at a high cutting speed aids the easy removal of the
metal during cutting. This may be attributed to the fact that with the
increasing cutting speed, results in the increase in temperature in the cutting
zone, thereby reducing the cutting force thus contributing smooth surface
finish, as observed from micrographs in the Figure 5.54 (a-d).
5.8.4 Effect of Machining Parameters on Flank Wear
flank wear at different depths of cut, which can help in the prediction of the
flank wear at any zone of the experimental domain.
(a) Flank Wear at 0.50 mm depth of cut

233
(b) Flank Wear at 0.75 mm depth of cut
(c) Flank Wear at 1 mm depth of cut

Different Depths of Cut for Whisker Reinforced Ceramic
Insert
Figures 5.56 (a-c) illustrate the 3D response surface plots for the
middle level. It is clear that the lowest flank wear is obtained at the middle
level of the cutting speed, and low level of feed rate and depth of cut. It is
234
found that the flank wear varies between the range of 0.24-0.435 mm in
machining nimonic C-263 alloy under different level of machining parameters
using the whisker reinforced ceramic insert.
(a) 3D response surface plots for flank wear at 0.75 mm depth of cut
(b) 3D response surface plots for flank wear at 190 m/min cutting speed
(c) 3D response surface plots for flank wear at 0.102 mm/rev feed rate
Figure 5.56 (a-c) 3D Response Surface Plots for Flank Wear using
235
speeds on the progression of flank wear. From the illustration, it is observed
that the rate of progression of the flank wear is relatively more with the feed
rate than with the cutting speed, signifying the better tolerance of the whisker
reinforced ceramic insert to higher speed.
The better tolerance to the higher cutting speed could be mainly due
to the higher hot hardness property of the ceramic insert. In addition, it also
shows that feed rate control is more important than cutting speed control,
while turning the nimonic C-263 alloy, using a whisker reinforced ceramic
insert. Further, Figure 5.57 indicates that the lowest flank wear results at the
middle level of the cutting speed and low level of the feed rate.
0.5
0.4
0.3

0.1
0.05 0.102 0.143
Feed rate (mm/rev)
Figure 5.57 Effect of Feed Rate on Flank Wear at Different Cutting

Speeds
Figure 5.58 indicates that the flank wear increases with an increase
in the depth of cut. The flank wear is considerably lower with an increase in
the cutting speed than with the depth of cut. The increase in the flank wear
with increased depth of cut could be due to the progressive damage of the
cutting edge, and the corresponding increase in contact between the tool edge
and the machined surface. This result indicate that the frictional heat
generated due to contact between the wornout tool and the work material is
more significant than the heat generation due to an increase in the cutting
236
speed, while machining the nimonic C-263 alloy. Further, Figure 5.58
indicates that the occurrence of a lower flank wear at a middle level of the
cutting speed and lower level of the depth of cut.
0.5
0.45
0.4
0.35
0.3
0.25
depth of cut = 1 mm
0.1
125 190 250
Figure 5.58 Effect of Cutting Speed on Flank Wear at Different Depths

of Cut
Figure 5.59 indicates that the flank wear increases with the increase
feed rate and depth of cut. However, the increase in the flank wear is
relatively more with the feed rate than with the depth of cut. At a high feed
rate and high depth of cut, the flank wear observed is 0.40 mm, which is
considerably higher than the flank wear value of 0.29 mm observed at a low
feed rate and low depth of cut. Figures 5.57 - 5.59 show the effect of the
selected parameters on the progression of the flank wear.
0.5
0.4
0.3

0.1
0.5 0.75 1
Depth of cut (mm)
237
The results show that the influence of the feed rate and depth of cut
is more significiant while machining the nimonic C-263 alloy with a whisker
reinforced ceramic insert. The change in the geometry of the cutting edge can
be seen distinctly from the SEM micrograph shown in Figure 5.60. The EDS
pattern shown in Figure 5.61 confirms that besides oxygen, the transferred
layer consists of traces of work piece elements such as Ni, Ti, Al, Mo, Cr and
Co. The EDS analysis of the worn out insert was also conducted at a location
indicated by the mark in the SEM image, to confirm the transfer of the
composition as shown in Figure 5.61.
Figure 5.60 SEM Micrograph of the worn region of the cutting edge.
Cutting conditions:V- 250m/min,S-0.143mm/rev, a p-0.75mm
Figure 5.61 EDS Analysis which Examined the Marked Cross Hair
Point in the Cutting Edge
238
Figure 5.62 (a-d) shows the status of the whisker reinforced

ceramic worn out insert under different cutting conditions. The main wear
mechanisms observed in the machining of the nimonic C-263 alloy using a
whisker reinforced ceramic insert, are abrasion, adhesion and diffusion. The
notch wear is severe in machining the nimonic C-263 alloy using the whisker
reinforced ceramic insert as this insert possesses low toughness values.
(a) Worn out insert at cutting (b) Worn out insert at cutting
speed of 250m/min, feed rate of speed of 190 m/min, feed rate
0.143 mm/rev and depth of of 0.102 mm/rev and depth
cut of 1mm of cut of 1mm
(c) Worn out insert at cutting (d) Worn out insert at cutting
speed of 125 m/min, feed rate of speed of 125 m/min, feed rate of
0.102 mm/rev and depth of cut of 0.143 mm/rev and depth of cut
0.75 mm of 0.75mm
Figure 5.62 (a-d) SEM Micrograph of the Worn Cutting Edge at

Different Cutting Conditions for Whisker Reinforced
Ceramic Insert
239

RSM AND ANN MODEL VALUES
The comparison between the experimental results, predicted values

by Response Surface Methodology and predicted by Artificial Neural
Network were evaluated for the responses such as the cutting force,
nimonic C-263 alloy using whisker reinforced ceramic insert.
nimonic C-263 alloy using whisker reinforced ceramic insert is shown in
Table 5.5. From the Table 5.5, a good aggrement is obtained between the
actual experimental results and predicted values based on RSM model,
indicating the effectiveness of prediction of cutting force, temperature at tool
tip, surface roughness and flank wear with 95% confidence levels during the
machining of the nimonic C-263 alloy using whisker reinforced ceramic
insert.

tool tip, surface roughness and flank wear between the experimental and ANN
model values were 0.855%, 1.27%, 2.04%, and 2.87% respectively.
The average percentage error for the responses such as the cutting
force, temperature at tool tip, surface roughness and flank wear between the
experimental and RSM model values were 1.90%, 2.69%, 3.75%, and 1.74%
respectively.
240
Table 5.5 Experimental and Model Results for Whisker Reinforced

Insert
Expt Experimental Values RSM Values

(N) C) (µm) (mm) (N) C) (µm) (mm)
1 450 365 3.25 0.275 449 352 3.09 0.28
2 485 385 2.75 0.3 499 377 2.68 0.29
3 540 405 2.25 0.32 551 406 2.40 0.32
4 490 445 3.5 0.31 488 448 3.47 0.30
5 570 475 3 0.325 546 475 3.10 0.33
6 630 500 2.85 0.345 606 507 2.87 0.35
7 550 525 3.75 0.36 561 529 3.86 0.34
8 625 545 3.6 0.37 625 558 3.53 0.37
9 680 605 3.4 0.38 690 592 3.34 0.40
10 420 435 2.45 0.24 408. 463 2.58 0.25
11 445 480 2.3 0.27 441 486 2.26 0.27
12 495 505 2.2 0.30 477 513 2.09 0.29
13 440 545 3 0.25 449 540 3.02 0.27
14 470 580 2.55 0.295 490. 565 2.76 0.29
15 510 610 2.65 0.315 533 595 2.62 0.32
16 540 625 3.5 0.28 523 606 3.48 0.30
17 575 635 3.3 0.32 570 633 3.25 0.32
18 620 655 3.25 0.39 619 665 3.15 0.36
19 390 545 2 0.40 390 539 2.11 0.37
20 410 575 1.9 0.36 408 560 1.89 0.38
21 420 590 1.8 0.38 428 586 1.80 0.40
22 425 600 2.75 0.35 433 598 2.62 0.37
23 460 615 2.55 0.415 459 622 2.44 0.39
24 500 635 2.45 0.43 485 650 2.40 0.42
25 510 645 3.15 0.41 509. 650 3.12 0.39
26 545 665 2.95 0.40 540 675 2.99 0.42
27 570 720 2.8 0.435 573 706 2.98 0.45
241
Table 5.6 Percentage Error Between the Experimental, RSM and

ANN with Respect to Whisker Reinforced Ceramic Insert
Exp % error % error

No Experimental Vs RSM Experimental Vs ANN
Fz, , Ra, VB, Fz, , Ra, VB,
(N) C) (µm) (mm) (N C) (µm) (mm)
1 0.22 4.92 1.81 3.56 0 5.75 0.61 1.81
2 2.88 2.54 3.33 2 0.20 1.81 6.90 3.33
3 2 6.66 0 0.24 0 0.49 3.11 3.33
4 0.40 0.85 3.22 0.67 0.20 0.22 1.14 3.22
5 4.21 3.33 1.53 0 0 1.89 0.33 1.53
6 3.80 0.70 1.44 1.4 3.80 0.80 0.35 1.44
7 2 2.93 5.55 0.76 0 4.57 4.53 2.77
8 0 1.94 0 2.38 0 0.73 2.22 0
9 1.47 1.76 5.26 2.14 0.88 4.95 4.11 0
10 2.85 5.30 4.10 6.43 0.23 3.21 1.22 8.33
11 0.89 1.73 0 1.25 0 1.25 3.04 0
12 3.6 5 3.33 1.58 0.20 0.39 2.72 3.33
13 2 0.66 8 0.91 3.63 0.36 0.33 8
14 4.25 8.23 1.69 2.58 1.06 0.34 0.78 5.08
15 4.50 1.13 1.58 2.45 0 1.14 0 1.58
16 3.14 0.57 7.14 3.04 0 0.16 0.57 3.57
17 0.86 1.51 0 0.31 2.78 2.36 0.60 3.12
18 0.16 3.07 7.69 1.52 2.25 0.76 0.92 2.56
19 0 5.5 7.5 1.10 0.15 0.18 2.5 2.50
20 0.48 0.52 5.55 2.60 0.48 0.34 1.05 0
21 1.90 0 5.26 0.67 0.23 0 8.33 10
22 1.88 4.72 5.71 0.33 0.23 0.50 0.25 5.71
23 0.21 4.31 6.02 1.13 0 0.48 5.88 1.5
24 3 2 2.38 2.36 6.6 1.57 2.44 2.32
25 0.19 0.95 4.87 2.25 0.19 0.19 1.26 2.43
26 0.91 1.35 5 1.50 8.25 0.75 1.69 0
27 0.52 0.64 3.44 1.94 0 8.33 0.35 1.5

respectively. These results indicated that the prediction of the responses such
242
as cutting force, temperature at tool tip, surface roughness and flank wear
with ANN model seems to have reasonable good prediction potential while
machining nimonic C-263 alloy using whisker reinforced ceramic insert.
Further, ANN model takes lesser computational time while giving better
accuracy. The models designed by ANN and RSM models would be helpful
to predict these responses during machining of the nimonic C-263 alloy using
whisker reinforced ceramic insert.
9
8 Fz Ra VB
7
6
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627
Experiment Number
(a) Percentage error between the experimental results and RSM predicted Values for
whisker reinforced ceramic insert
12
11 Fz Ra VB
10
9
8
7
6
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 10 1112131415 16 171819202122 23 24 252627
Experiment Number
(b) Percentage error between the Experimental results and ANN predicted Values for
whisker reinforced ceramic insert
Figure 5.63 (a-b) Percentage Error Among the Experimental results, RSM
and ANN Predicted Values for Whisker Reinforced Ceramic
Insert
243
5.10 CONFIRMATION EXPERIMENT FOR OPTIMAL

SOLUTION USING WHISKER REINFORCED CERAMIC
INSERT

solutions obtained based on Response Surface Method based desirability
approach in machining the nimonic C-263 alloy using whisker reinforced
ceramic insert. The confirmation experiments were performed in the
following range of the input parameters: cutting speed-181 m/min, feed rate-
0.05 mm/rev and depth of cut-0.57 mm. The plan for the confirmation
experiment and the values of Fz, , Ra and VB, obtained by the confirmation
experiment, and predicted through the optimization approach are given in
Table 5.7. The results indicated that the predicted values are very close to
those of the experimental results.
Table 5.7 Plan of the Confirmation Experiments and Results for

Fz (N) (°C) Ra ( m) VB (mm)

S. V S ap Predicte
Predicte Experimenta Predicte Experimenta d Experimenta Predicte Experimenta
N (m/min (mm/rev (mm
d l d l l d l
o ) ) ) Values
Values Results Values Results Results Values Results
1 181 0.05 0.57 422 420 456 450 2.53 2.65 0.25 0.23
2 181 0.05 0.57 422 415 456 460 2.53 2.50 0.25 0.22
3 181 0.05 0.57 422 425 456 465 2.53 2.48 0.25 0.24
5.11 ON-LINE TOOL WEAR MONITORING
In this research work, an attempt has also been made to monitor the
status of the whisker reinforced ceramic insert by acquiring AE signal while
turning nimonic C-263 alloy at different cutting speed and feed rate at
constant depth of cut.
244
5.11.1 Monitoring of Acoustic Emission for Whisker Reinforced

Ceramic Insert
The Figure 5.64 (a-f) shows the Acoustic Emission (AE) signals
when turning the nimonic C-263 alloy at different cutting conditions. When
turning the nimonic C-263 alloy at cutting speeds of 125 m/min and 190
m/min with feed rates of 0.102 mm/rev and 0.143 mm/rev, the cutting edge
undergoes running in wear significantly thus responding with spreaded
frequency acoustic emission around in the range of 40-100 kHz with low FFT
magnitude as seen from the Figure 5.64 (a-d) by the presence of dominant
peaks.
Also when the tool is sharp the chip breakage will be better there
by producing a smaller magnitude signal as there is gradual and uniform tool
flank wear. The occurrence of higher amplitude frequency components in the
lower range FFT magnitude indicates the wearing of tool. When the tool
fracture occurs, the tool damage is signified with production of strong AE
signal, correspondingly very large and wide frequency components are seen
even beyond 400 kHz, together with low frequency components as seen in the
Figures 5.64 (a-d).
Typical FFT of the AE signals generated at different tool conditions

when turning nimonic C-263 alloy at higher cutting speed of 250 m/min, with
respect to the feed rate of 0.102 mm/rev and 0.143 mm/rev are shown in
Figure 5.64 (e-f). At higher combination of cutting speed and feed rate, the
strain rate is high and the resisting cross section under the cutting edge due to
higher feed rate is also more. The increase in the flank wear with increasing
cutting speed and feed rate could be attributed to the progressive damage of
the cutting edge, and the corresponding increase in contact between the tool
edge and the machined work surface.
245
Due to this, the energy of the signal produced when turning the
nimonic C-263 alloy using whisker reinforced ceramic insert is high as seen
from the Figures 5.64 (e to f), i.e. the signal is spread in wider range, than at
lower combinations of cutting conditions. As tool flank wear increases, an
increase in the amplitude of the signal seen with high FFT magnitude. Apart
from the occurrence of low frequency components of 40-100 kHz as seen
from the lower cutting conditions, dominant peaks are also seen at frequencies
of 150 kHz, 200 kHz, 250 kHz, 300 kHz, and 400 KHz which may possibly
due to higher order stressing of the material at higher cutting speed indicating
worn out status of the whisker reinforced ceramic tool insert.
It can be concluded that, the presence of dominant peaks of AE

signal acquired when turning nimonic C-263 alloy around the frequency of
350 kHz, irrespective of tool condition and cutting conditions can be
attributed to the response of the nimonic C-263 alloy when turning using
whisker reinforced ceramic insert.
(a) Fast Fourier Transform of Acoustic Emission at cutting speed of

125 m/min, feed rate of 0.102 mm/rev and depth of cut of 0.75 mm
246
(b) Fast Fourier Transform of Acoustic Emission at cutting speed of

(C) Fast Fourier Transform of Acoustic Emission at cutting speed of

190 m/min, feed rate of 0.102 mm/rev and depth of cut of 0.75 m
(d) Fast Fourier Transform of Acoustic Emission at cutting speed of

247
(e) Fast Fourier Transform of Acoustic Emission at cutting speed of 250

m/min, feed rate of 0.102 mm/rev and depth of cut of 0.75 m
(f) Fast Fourier Transform of Acoustic Emission at cutting speed of 250

Figure 5.64 (a-f) FFT of Acoustic Emission at Different Cutting
Conditions for Whisker Reinforced Ceramic Insert

RESPONSES IN TURNING NIMONIC C- 263 ALLOY
USING CUBIC BORON NITRIDE (CBN).

evaluated and analysed in turning nimonic C-263 alloy cubic boron nitride.
248
5.12.1 Effect of Machining Parameters on Cutting Force
each of the cutting force at different depths of cut. These response contours
can help in the prediction of the cutting force at any zone of the experimental
domain.

249
(c) Cutting force at 0.75 mm depth of cut

Different Depths of cut for Cubic Boron Nitride Insert
middle level. It is clear from these figures that the cutting force is high at
lower cutting speed and at a higher feed rate. The cutting force is reduced
when the level of depth of cut and feed rate is reduced. It is found that the
cutting force (Fz) varies between the range 265-550 N when machining
nimonic C-263 alloy under different level of machining parameters using
cubic boron nitride insert.
(a) 3D response surface plots for cutting force at 0.50 mm depth of cut
250
(b) 3D response surface plots for cutting force at 125 m/min cutting speed
(c) 3D response surface plots for cutting force at 0.096 mm/rev feed rate
Figure 5.66 (a-c) 3D Response Surface Plots for Cutting force using
Cubic Boron Nitride Insert
From Figure 5.67, it is observed that the maximum magnitude of

the cutting force component is 526 N, at a lower level of cutting speed and a
higher level of depth of cut .The cutting force tends to increase at a low
cutting speed and at all levels of the depths of cut.
251
525
450
375
300
150
80 125 190
Figure 5.67 Effect of Cutting speed on Cutting Force at Different Depths

of Cut
From Figure 5.68, it is observed that the cutting force tends to

increase when the feed rate increases, for all levels of cutting speed. Further it
is observed that, the maximum cutting force of 510 N is generated at a higher
level feed rate and a middle level of cutting speed. Further, it is observed that
the cutting forces was high at lower and middle level of cutting speed than
higher level of cutting speed due to the high coefficient of friction between
the tool and the work material, compared to that of higher cutting speed. The
increase of temperature is greater at a higher cutting speed causing softening
of the work material, and thereby reducing the cutting force.
550
500
450
400
350
300
150
0.055 0.096 0.159
Feed rate (mm/rev)
Figure 5.68 Effect of Feed Rate on Cutting Force at Different Cutting
Speeds
252
Figure 5.69 shows that the magnitude of the cutting force

component tends to increase, as the level of the feed rate and depth of cut
increases. The maximum cutting force of 508 N is observed at a higher level
of depth of cut and feed rate.
525
450
375
150
0.25 0.5 0.75
Depth of cut (mm)
Figure 5.69 Effect of Depth of Cut on Cutting Force at Different Feed Rates
At a higher feed rate the cutting force increases as the flank wear
increases, which are evidently seen in Figure 5.70. The increase in the flank
wear at a higher feed rate is due to the damage of the cutting edge, creating
the abrasion between the tool edge and work piece surface, thus the
generation of the cutting force is also high.
500
0.35
450
0.25
400
350 0.15
Cutting force
flank wear
300 0.05
0.055 0.096 0.159
Feed rate (mm/rev)
cutting speed of 125 m/min and depth of cut 0.50 mm
253
5.12.2 Effect of Machining Parameters on Temperature at Tool Tip
temperature at tool tip at different depths of cut. These response contours can
help in the prediction of the temperature rise at tool tip at any zone of the

254
(c) Temperature at tool tip at 0.75 mm depth of cut
Figure 5.71 (a-c) Temperature at Tool Tip contours in Velocity- Feed

Plane at Different Depths of Cut for Cubic Boron Nitride
Insert
temperature rise at tool tip. It is clear from these figures that the temperature
rise at tool tip is high at higher cutting speed and feed rate. The temperature at
tool tip gets reduced when the level of depth of cut and feed rate is reduced. It
is found that the temperature at tool tip varies between the range of 390-
740°C while machining nimonic C-263 alloy under different level of
machining parameters using the cubic boron nitride insert.
(a) 3D response surface plots for temperature at tool tip at 0.50 mm depth of cut
255
(b) 3D response surface plots for temperature at tool tip at 0.096 mm/rev feed rate
(c) 3D response surface plots for temperature at tool tip at 125 m/min cutting speed
Figure 5.72 (a-c) 3D Response Surface Plots for Temperature at Tool

Tip using Cubic Boron Nitride Insert
From Figure 5.73, it is observed that the magnitude of the

temperature at tool tip tends to increase when the feed rate and cutting speed
increases and also, it is observed that, the maximum of temperature 705 C is
observed at a higher level feed rate and cutting speed. Increasing both the
cutting speed and feed rate causes the concentration of higher temperature
very close to the cutting edge there by developing the notching and flank
wear.
256
725
650
575
350
0.055 0.096 0.159
Feed rate (mm/rev)
Figure 5.73 Effect of Feed Rate on Temperature at Tool Tip at Different

Cutting Speed
From Figure 5.74, it is observed that the temperature at tool tip is

681 C at a higher level of cutting speed and depth of cut. From Figure 5.75, it
is observed that the temperature at tool tip tends to increase, when the level of
the feed rate and the depth of cut increases. The maximum of temperature
688 C is observed at higher level of depth of cut and feed rate. From Figures
5.73-5.75, it is observed that the temperature at tool tip increases with the
increase in the level of cutting speed, feed rate and depth of cut.
700
625
550
400
80 125 190

257
700
650
600
550
400
0.25 0.5 0.75
Depth of cut (mm)

Different Feed Rate
5.12.3 Effect of Machining Parameters on Surface Roughness
surface roughness at different depths of cut, which can help in the prediction
of the surface roughness at any zone of the experimental domain.

258
(c) Surface roughness at 0.75 mm depth of cut
Figure 5.76 (a-c) Surface Roughness contours in Velocity- Veed Plane at

Different Depths of Cut for Cubic Boron Nitride Insert
Figures 5.77 (a-c) illustrate the 3D response surface plots for

model by varying the two different parameters, and keeping the third
parameter at the middle level. It is clear from these figures, that the lowest
surface roughness is obtained at higher level of cutting speed and depth of cut
and at low level of feed rate. It is found that the surface roughness varies
between the range of 1.45 - 3.1 µm while machining nimonic C-263 alloy
under different level of machining parameters using the cubic boron nitride
insert.
259
(a) 3D response surface plots for surface roughness at 0.50 mm depth of cut
(b) 3D response surface plots for surface roughness at 0.096 mm/rev feed rate
(c) 3D response surface plots for surface roughness at 125 m/min cutting speed
Figure 5.77 (a-c) 3D Response Surface Plots for Surface Roughness

using Cubic Boron Nitride Insert
260
speeds on the surface roughness. From the illustration, it is observed that as
feed rate increases the surface roughness increases. However, the surface
roughness reduced while increasing the cutting speed.
3.5
3
2.5
2
1
0.25 0.5 0.75
Feed rate ( mm/rev)
Figure 5.78 Effect of Feed rate on Surface Roughness at Different
Cutting Speeds
Figure 5.79 shows the effect between the feed rate and the depth of
cut on the surface roughness. From the illustration, it is seen that the increase
in the feed rate increases the surface roughness, whereas relatively better
surface roughness is observed at the combination of higher level of the depth
of cut and a lower level of the feed rate. It is observed for higher depth of cut,
a reduction in the surface roughness. This is because, at a higher depth of cut,
the surface layer may get work hardened, thus leading to a reduction in the
surface roughness.
3.5
3
2.5
2
1
0.25 0.5 0.75
Depth of cut ( mm)
Figure 5.79 Effect of Depth of Cut on Surface Roughness at Different
Feed Rates
261
Figure 5.80 shows that the increase in the depth of cut and cutting
speed reduces the surface roughness. The surface roughness observed at a
higher level of depth of cut and cutting speed is lower than the surface
roughness observed at a lower level of depth of cut and cutting speed.
3.5
3
2.5
2
0.5
80 125 190

Depths of Cut
The higher significance of the feed rate over cutting speed and
depth of cut indicates the rubbing of the worn flank, and the associated
change in the surface roughness. This is clearly shown in Figure 5.81 (a-c), in
which the surface roughness tends to increase, as the flank wear rate increases
at all levels of the cutting speed. In addition, the low thermal conductivity of
the nimonic C-263 alloy contributes to the generation of heat in the tool work
contact zone.
(a) Effect of feed rate on flank wear and surface roughness at cutting
speed of 80m/min and depth of cut of 0.50 mm
262
0.4 3.9
0.35
3.4
0.3
0.25 2.9
0.2 2.4
0.15
0.1
Cutting force 1.9
Surface roughness
0.05 1.4
0.055 0.096 0.159
Feed rate (mm/rev)
0.5
3.2
0.4
2.7
0.3
2.2
flank wear
0.2 Surface roughness 1.7
0.1 1.2
0.055 0.096 0.159
Feed rate (mm/rev)
(c) Effect of feed rate on flank wear and surface roughness at cutting
Roughness at All Level of Cutting Speed for Cubic Boron
Nitride Insert
263
Figure 5.82 (a-d) shows the SEM micrographs of the machined

surface under different cutting conditions. It indicates the status of the
machined surface, in terms of the smeared surface, feed marks, chip particles,
long grooves, streak, and metal debris. These surface status are generally
attributed to the generation of forces and temperatures rise at the cutting zone,
and also the deformation on the flank face, and adherence of the work piece
material.
At a lower cutting speed there could be an adherence of the chip on

the tool surface, and due to the pressure weld between the tool and the chip,
which may randomly pluck and scratch the machined surface. Further, the
possible periodical removal of aggregates of the tool material and the
corresponding acceleration of wear could have resulted the associated
impairing of the machined surface, as seen from the micrographs in the Figure
5.82 (a-d).
The increase in temperature at a high cutting speed aids easy

removal of the metal while cutting. This is attributed to the fact that with the
increasing the cutting speed, causing rise in temperature in the cutting zone,
thereby reducing the cutting force; and improving surface finish, as seen
from micrographs given in the Figure 5.82 (a-d).
264
(a)SEM Micrographs of machined (b)SEM Micrographs of machined

surface at cutting speed of 80m/min, surface at cutting speed of 125
feed rate of 0.159 mm/rev and depth m/min, feed rate of 0.159 mm/rev
of cut of 0.75 mm and depth of cut of 0.75 mm
(c)SEM Micrographs of machined (d)SEM Micrographs of machined

surface at cutting speed of 190m/min, surface at cutting speed of
feed rate of 0.096 mm/rev and depth 190m/min, feed rate of 0.159
of cut of 0.75 mm mm/rev and depth of cut of
0.75 mm

Cutting Conditions using Cubic Boron Nitride Insert
5.12.4 Effect of Machining Parameters on Flank Wear
flank wear at different depths of cut, which can help in the prediction of the
flank wear at any zone of the experimental domain.
265
(a) Flank Wear at 0.25 mm Depth of Dut
(b) Flank Wear at 0.50 mm Depth of Cut
(c) Flank Wear at 0.75 mm Depth of Cut

Different Depths of cut for Cubic Boron Nitride Insert
266
Figures 5.84 (a-c) illustrate the 3D response surface plots for the
middle level. It is also clear from these figures that the lowest flank wear is
obtained at the middle level of the cutting speed, and lower level of feed rate
and depth of cut. It is observed that the flank wear varies between the range of
0.29-0.48 mm while machining nimonic C-263 alloy under different levels of
machining parameters using the cubic boron nitride insert.
(a) 3D response surface plots for flank wear at 0.50 mm depth of cut
(b) 3D response surface plots for flank wear at 0.096 mm/rev feed rate
267
(c) 3D response surface plots for flank wear at 125 m/min cutting speed
Figure 5.84 (a-c) 3D Response Surface Plots for Flank Wear using Cubic
Boron Nitride Insert
speeds on the progression of flank wear. From the illustration, it is observed
that the rate of progression of the flank wear is more with the feed rate than
with the cutting speed. The lowest flank wear is observed at middle level of
the cutting speed and low level of the feed rate.
0.5
0.4
0.3
0.1
0.055 0.096 0.159
Feed rate (mm/rev)
Figure 5.85 Effect of Feed Rate on Flank Wear at Different Cutting

Speeds
Figure 5.86 indicates that the flank wear increases with an increase
in the depth of cut. The increase in flank wear is considerably lower with an
increase in the cutting speed than with the depth of cut. The increase in the
flank wear with increased depth of cut could be attributed to the progressive
268
damage of the cutting edge, and the corresponding increase in contact area
between the cutting edge and the machined work surface. The lower flank
wear is observed at middle level of the cutting speed and lower level of the
depth of cut.
0.5
0.45
0.4
0.35
0.3
0.25
0.1
80 125 190
Figure 5.86 Effect of Cutting speed on Flank wear at Different Depths of

Cut
Figure 5.87 indicates that the flank wear increases with the feed
rate and depth of cut. However, the rate of increase of the flank wear is more
significant with the feed rate than with the depth of cut. At a higher feed rate
and higher depth of cut, the observed flank wear is 0.42 mm, which is
considerably higher than the flank wear value of 0.33 mm observed at a low
feed rate and low depth of cut.
0.5
0.4
0.3
0.1
0.25 0.5 0.75
Depth of cut (mm)
269
The results show that the influence of the cutting speed and feed
rate is more significant process parameter while machining the nimonic C-263
alloy with a cubic boron nitride insert. The change in the geometry of the
cutting edge when machining the nimonic C-263 alloy at different cutting
conditions can be seen distinctly from the SEM micrograph given in
Figure 5.88. The wear mechanisms observed in the machining of the nimonic
C-263 alloy using a cubic boron nitride insert are micro chipping, adhesion as
evident in the Figure 5.88 (a-d).
(a)SEM Micrograph of the Worn out (b)SEM Micrograph of the Worn out
Cutting Edge at Cutting speed of Cutting Edge at Cutting speed of
190m/min, feed rate of 0.159 mm/rev 190m/min, feed rate of 0.096 mm/rev
and depth of cut of 0.75mm and depth of cut of 0.75mm
(c)SEM Micrograph of the Worn (d)SEM Micrograph of the Worn out

out Cutting Edge at Cutting speed of Cutting Edge at Cutting speed of 80
125 m/min, feed rate of 0.055 m/min, feed rate of 0.159 mm/rev and
mm/rev and depth of cut of 0.75mm depth of cut of 0.75mm
Figure 5.88 (a-d) SEM Micrograph of the Worn Out Cutting Edge at
Different Cutting Conditions using Cubic Boron Nitride
Insert
270

RSM AND ANN MODEL VALUES FOR CUBIC BORON
NITRIDE INSERT
The comparison between the experimental results , predicted values

by Response Surface Methodology and predicted by Artificial Neural
Network were evaluated for the responses such as the cutting force,
nimonic C-263 alloy using Cubic Boron Nitride insert.
nimonic C-263 alloy using cubic boron nitride insert is shown in Table 5.8.
From the Table 5.8, a good aggrement is obtained between the actual
experimental results and predicted values based on RSM model, indicating
the effectiveness of prediction of cutting force, temperature at tool tip, surface
roughness and flank wear with 95% confidence levels during the machining
of the nimonic C-263 alloy using cubic boron nitride insert.

tool tip, surface roughness and flank wear between the experimental and ANN
model values were as1.57%, 1.07%, 1.48%, and 3.55% respectively. The
average percentage error for the responses such as the cutting force,
temperature at tool tip, surface roughness and flank wear between the
experimental and RSM model values were as 3%, 5.06 %, 2.76%, and 1.94%
respectively.
271
Table 5.8 Experimental and Model Results for Cubic Boron Nitride
Insert
Experimental Values RSM Values

Expt Fz Ra VB Fz Ra VB
No (N) (µm) (mm) C) (N) (µm) (mm) C)
1 400 2.55 0.3 390 409 2.52 0.30 386
2 440 2.2 0.32 410 451 2.35 0.32 420
3 490 2.35 0.34 430 496 2.20 0.34 453
4 450 2.8 0.33 480 433 2.86 0.33 498
5 500 2.6 0.35 530 476 2.70 0.35 529
6 540 2.4 0.36 580 521 2.56 0.37 559
7 460 3.1 0.38 600 476 3.02 0.36 592
8 520 3 0.39 625 519 2.87 0.38 619
9 550 2.8 0.40 660 565 2.73 0.41 646
10 300 2.25 0.29 480 290 2.18 0.29 483
11 330 2.1 0.31 545 327 2.00 0.31 514
12 380 1.7 0.33 560 366 1.85 0.33 544
13 325 2.65 0.30 590 335 2.65 0.32 575
14 345 2.55 0.345 610 372 2.49 0.33 603
15 390 2.65 0.365 620 412 2.34 0.36 630
16 420 2.93 0.32 640 401 2.96 0.34 645.
17 440 2.6 0.36 650 439 2.80 0.36 669
18 495 2.5 0.41 665 479 2.66 0.39 693.
19 265 1.6 0.42 570 255 1.76 0.39 577
20 290 1.65 0.38 600 283 1.58 0.41 604.
21 300 1.45 0.42 630 314 1.41 0.43 630
22 310 2.65 0.39 640 329. 2.43 0.41 639
23 360 2.15 0.45 660 358 2.25 0.43 663
24 410 1.9 0.46 675 389 2.09 0.45 685
25 430 2.8 0.45 685 428 2.94 0.43 676.
26 465 2.95 0.44 690 458 2.77 0.45 696
27 480 2.7 0.47 740 490 2.62 0.48 715
272
Table 5.9 Percentage Error Between the Experimental, RSM and

ANN with Respect to Cubic Boron Nitride Insert
Expt % error % error

No Experimental Vs RSM Experimental Vs ANN
Fz Ra VB Fz Ra VB
(N) C) (µm) (mm) (N C) (µm) (mm)
1 2.25 1.17 0 1.02 7.25 5.38 6.66 3.33
2 2.5 6.8 0 2.43 0.22 1.21 5 0
3 1.22 6.38 0 5.34 0 0.23 0.42 0
4 3.77 2.14 0 3.75 2.88 0.20 0 0
5 4.8 3.84 0 0.18 0 0 0.38 0
6 3.51 6.66 2.77 3.62 1.11 0.17 0 2.77
7 3.41 2.58 5.26 1.33 0.21 0.16 0.96 5.26
8 0.19 4.33 2.56 0.96 2.11 0 0 2.56
9 2.72 2.5 2.50 2.12 2.18 1.51 0 0
10 3.33 3.11 0 0.62 0.33 0 7.11 6.89
11 0.90 4.76 0 5.68 0.60 5.32 0 0
12 3.68 8.82 0 2.85 9.73 0.17 2.94 3.03
13 3.07 0 6.66 2.54 3.38 0.16 0.37 6.66
14 7.82 2.35 4.34 1.14 0.28 0 0 0.43
15 5.64 11 1.36 1.61 0.25 2.41 0 5.55
16 4.52 1.02 6.25 0.78 0.23 2.18 2.85 3.125
17 0.22 7.69 0 2.92 0.22 0.15 0.38 2.77
18 3.23 6.4 4.87 4.21 0.20 0.15 0 9.75
19 3.77 10 7.14 1.22 3.01 0 0.625 7.14
20 2.41 4.24 7.89 0.66 0.34 0.16 0.60 5.26
21 0.31 4 2.38 0 0.33 0 5.51 0
22 6.12 8.30 5.12 0.15 4.19 0 0 5.12
23 0.55 4.65 4.44 0.45 3.05 0 0.46 4.44
24 0.21 10 2.17 1.48 0.24 0 0.52 6.52
25 0.46 5 4.44 1.31 0.23 0 0 6.66
26 1.50 6.10 2.27 0.86 0.21 0.86 2.86 2.27
27 2.08 2.96 2.12 3.37 0 1.35 2.54 6.38
273

respectively. These results indicated that the prediction of the responses such
as cutting force, temperature at tool tip, surface roughness and flank wear
with ANN model seems to have the prediction potential in machining of
nimonic C-263 alloy using cubic boron nitride insert and the ANN model
consumes lesser computational time and giving higher accuracy. The models
designed by ANN and RSM models would be helpful to predict these
responses during the machining of the nimonic C-263 alloy using cubic boron
nitride insert.
(a) Percentage error between the experimental results and RSM

predicted values for Cubic Boron Nitride Insert
12
10.5 Fz Ra VB
9 (b)
7.5
6
4.5
3
1.5
0
1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627
Experiment Number
(a) Percentage error between the experimental results and ANN

predicted Values for cubic boron nitride insert
12
10.5 Fz Ra VB
9
7.5
6
4.5
3
1.5
0
1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627
Experiment Number
Figure 5.89 (a-b) Percentage Error Among the Experimental Results,
RSM and ANN Predicted Values for Cubic Boron Nitride
Insert
274
5.14 CONFIRMATION EXPERIMENT FOR OPTIMAL SOLUTION
USING CUBIC BORON NITRIDE INSERT

solutions obtained based on Response Surface Method based desirability
approach in machining the nimonic C-263 alloy using cubic boron nitride
insert. The confirmation experiments were performed in the following range
of the input parameters: cutting speed-134 m/min, feed rate-0.06 mm/rev and
depth of cut-0.25 mm. The plan for the confirmation experiment and the
values of Fz, , Ra and VB, obtained by the confirmation experiment, and
predicted through the optimization approach are given in Table 5.10. The
results indicated that the predicted values are very close to those of the
experimental results.
Table 5.10 Plan of the Confirmation Experiments and Results for

Cubic Boron Nitride Insert
Fz (N) (°C) Ra ( m) VB(mm)

Sol. V S ap
No. Predict Experimental Predict Experimental Experi-
(m/min ) (mm/rev) (mm) Predicted Experimental Predicted
ed ed mental
1 134 0.06 0.25 279 275 508 520 2.16 2.25 0.29 0.25
2 134 0.06 0.25 279 270 508 515 2.16 2.00 0.29 0.26
3 134 0.06 0.25 279 280 508 225 2.16 2.30 0.29 0.28
5.15 SURFACE INTEGRITY ANALYSIS IN TURNING

NIMONIC C-263 ALLOY
The quality and performance of a machined component are directly

related to the surface integrity. Therefore, the present work focuses on the
investigations on the surface integrity viz microhardness, and residual stresses
that are generated on the machined surface, while machining the nimonic C-
263 alloy using PVD coated carbide and whisker reinforced ceramic inserts.
275
5.15.1 Effect of Machining Parameters on Microhardness Variations

in Turning Nimonic C-263 Alloy Using PVD Coated Carbide
Insert
The plastic deformation of the microstructure occurs on the surface

zone of the work-piece because of machining, causing work hardening
thereby increasing the hardness of the work material. The degree and depth to
which the machined surface is hardened depend upon many factors. The most
important of these are the properties of the metal being machined, the
geometry of the cutting edge, the degree of tool wear, cutting conditions and
the use of the cutting fluid. The change in the microhardness of the work-
piece surface and sub surface, using PVD coated carbide insert in its own
functioning domain, was measured with the help of the Knoop indenter with a
load of 100g for 15s.
Figures 5.90-5.92 illustrate the variation of microhardness of the

nimonic C-263 alloy at different depths from the machined surface during
turning, using a PVD coated carbide insert cutting tool. It is observed from
that the microhardness value is higher near the machined surface layer, and it
decreases gradually with the increasing depth below the machined surface,
and approaches the average of the bulk material hardness of 320 HV. It can be
attributed to their work-hardening rate near the machined surface, and also
because of the heat and strain effects that are neutralized for the bulk material
below the machined surface (Durul Ulutana and Tugrul Oze 2007).
The microhardness of the machined surface is about 1.15 and 1.41

times the bulk material hardness (320 HV) with respect to the feed rates of
0.102 mm/rev and 0.143 mm/rev respectively, at a cutting speed of 22 m/min
and constant depth of cut of 0.75 mm. The microhardness value on the
machined surface was found approximately about 1.25 and 1.6 times that of
the bulk material hardness with respect to feed rates of 0.102 mm/rev and
276
0.143 mm/rev respectively, at a cutting speed of 33m/min and constant depth

of cut 0.75 mm for machining period of 9 minutes. The microhardness of the
machined surface was found to be approximately about 1.53 and 1.75 times
that of the bulk material hardness with respect to feed rates of 0.102 mm/rev
and 0.143 mm/rev respectively, at a cutting speed of 54m/min and constant
depth of cut 0.75 mm for machining period of 9 minutes.
As seen from all the Figures 5.90 - 5.92, the level of microhardness
of the machined surface also significantly increases with the machining time.
With an increase in the cutting time, the tool wear progressively grows, thus
inducing higher frictional contact between the tool and the work-piece,
ultimately leading to pressure induced plastic deformation rather than shear
deformation.
Figure 5.90 Microhardness Variations below the machined surface at

cutting speed of 22 m/min
277
Figure 5.91 Microhardness Variations below the Machined Surface at

Figure 5.92 Microhardness Variations Below the Machined Surface at

5.15.2 Effect of Machining Parameters on Residual Stresses in

Turning Nimonic C-263 Alloy using PVD Coated Carbide
Insert
As the nimonic C-263 alloy is metallurgically composed to have

high temperature strength and low thermal conductivity, it exhibits severe
278
work hardening, high cutting resistance and high localized temperature near
the tool work interface, which greatly contributes to residual stresses during
machining. In this study, residual stress measurements were made three times
at each point on the machined surface with respect to all cutting conditions
after finite time intervals of 3 min, 6 min, and 9 min. The typical Residual
Stress (RS) patterns produced in the cutting direction, while turning the
nimonic C-263 alloy in different cutting conditions, using PVD coated
carbide inserts are illustrated in Figures 5.93 - 5.95.
In all the cases it is found, that the residual stresses are more tensile
at the surface of the work-piece and become compressive as the depth of the
work-piece increases. The external residual stresses on the machined surface
are all tensile residual stresses, as the thermal loads prevail against the
mechanical loads, whereas the subsurface does not (Berruti et al 2009).The
external surface is plastified by compression. When cooling, the external
surface tends to recover its position, which is no longer possible due to plastic
deformation, leading to a tensile state. As illustrated in Figure 5.93, when the
tool is fresh, the maximum values of the surface tensile residual stresses of
about 100 MPa and 175MPa are recorded, while turning at the feed rates of
0.102 mm/rev and 0.143 mm/rev respectively, at a cutting speed of 22 m/min.
As the tool wears out, i.e., after cutting for 9min, the surface tensile residual
stresses rise to about 300MPa and 400MPa, with respect to feed rates of 0.102
mm/rev and 0.143mm/rev.
During the exposure to intense heat fluxes near the primary shear
zone and in the rubbing zone, a high temperature gradient exists, which may
lead to the local plastification of the work material. When the surface returns
to a steady state at room temperature, the tensile stresses remain at the
surface. Consequently, compressive stresses exist in the sub-surface. Further,
the residual stresses near the surface shifted towards compression as the feed
279
rate was increased, thus indicating the dominance of the mechanical load.
This is observed when the tool is fresh. However, such an effect is not
observed when the tool is used for a period of 9min thus diminishing the feed
rate effect, and instead, the prevalence of the tensile residual stress is more,
which indicates the dominance of the thermal load over the mechanical load.
From the Figure 5.94, it is observed that, as the cutting speed is increased, the
level and depth of the tensile residual stress increases. When the cutting speed
is increased, the generation of temperature increases, thus favouring the
thermal load.
As illustrated in Figure 5.95, the maximum values of the surface

tensile residual stresses are about 150 MPa and 350 MPa, with respect to the
feed rate of 0.102 mm/rev and 0.143 mm/rev respectively, for a machining
period of 3 minutes using a PVD coated carbide insert, at a cutting speed of
33 m/min. As the tool wears out, i.e., after cutting for 9min,the surface tensile
residual stresses rise to about 350MPa and 500MPa, with respect to feed rates
of 0.102 mm/rev and 0.143mm/rev. It is also shown from Figure 5.95, that,
the maximum values of the surface tensile residual stresses are about 250MPa
and 275MPa, with respect to the feed rate of 0.102 mm/rev and 0.143 mm/rev
respectively, for a machining period of 3 minutes using a PVD coated carbide
insert, at a cutting speed of 54 m/min. As the tool wears out, i.e., after cutting
for 9 min, the surface tensile residual stresses rise to about 525MPa and
625MPa, with respect to feed rates of 0.102 mm/rev and 0.143mm/rev.
The subsurface residual stresses measured at a cutting speed of

22m/min, 33m/min and 54m/min, beneath the machined surface of the
nimonic C-263 alloy using PVD coated carbide insert, in which the surface
tensile residual stresses rapidly drop to a compressive residual stress level up
to a depth of 0.2 mm; subsequently as the depth increases, the compressive
residual stresses reduced. The cutting edge preparation and the rake angle are
280
predominant factors controlling the distribution of stresses in the subsurface

layer. In this study, a PVD coated carbide cutting tool having a negative rake
(-6°) a with round cutting edge, and 0.8mm nose radius is used for turning.
Generally, the compressive zone expands visibly when cutting with a rounded
cutting edge and larger negative rake angles (Li et al 2002).
As a consequence, in such cases, the work-hardening effect will

probably be more intense due to the plowing effect. But due to its lower
thermal conductivity when compared to the nimonic C-263 alloy, most of the
generated heat is conducted through the work material, resulting in a thermal
load. However, the resultant load is thermal and hence, higher tensile residual
stresses are observed. Further, it is seen that after operating for 9 min of
cutting time at a cutting speed of 54m/min, a maximum of 1.56 times tensile
residual stress is observed at a cutting speed of 22 m/min.
500
S = 0.102mm/rev, t = 3 min
400 S = 0.102 mm/rev, t = 6 min
S = 0.102 mm/rev, t = 9 min
300 S = 0.143 mm/rev, t = 3 min
S = 0.143 mm/rev, t = 6 min
200 S = 0.143 mm/rev, t = 9 min
100
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
-200
-300
-400
-500
Depth beneath the surface (mm)
Figure 5.93 Residual Stresses at Cutting Speed of 22 m/min
281
600 S= 0.102 mm/rev, t = 3 min

500 S= 0.102 mm/rev, t = 6 min
S= 0.102 mm/rev, t = 9 min
400 S= 0.143 mm/rev, t = 3 min
S= 0.143 mm/rev, t = 6 min
300
200
100
0
-100 0 0.2 0.4 0.6 0.8
-200
-300
800
S= 0.102 mm/rev, t = 3 min
S= 0.102 mm/rev, t = 6 min
600 S= 0.102 mm/rev, t = 9 min
S= 0.143 mm/rev, t = 3 min
400 S= 0.143 mm/rev, t = 6 min
S= 0.143 mm/rev, t = 9 min
200
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
-200
-400
5.15.3 Effect of Machining Parameters on Microhardness in Turning

Nimonic C-263 Alloy using Whisker Reinforced Ceramic Insert
The chip formation mechanism is one of the stochastic processes,

involving both elastic and plastic deformation. During machining, the layer
being cut and the layer of the main mass of the metal is subject to severe
282
plastic deformation, and thus, there is an increase in the work material

hardness. Figures 5.96 (a-c) illustrate the variation in the microhardness of the
nimonic C-263 material at different depths from the machined surface during
turning, using a ceramic insert cutting tool. It is observed from the figures that
the microhardness value is higher near the machined surface layer, and it
decreases gradually at varies depth below the machined surface, and it
approaches the average of the bulk material hardness of 320HV.
The high pressures developed between the tool and the work piece
during turning, produce a stressed layer of deformed metal on the surface of
the work, and the deformation causes a hardening effect. The decrease in
hardening below the surface could be due to the neutralisation of the heat and
strain effects below the machined surface. The higher microhardness values
just underneath the machined surface could be attributed to the pile up of the
dislocation density due to plastic deformation. Particularly, in the case of the
nimonic C 263 alloy, the presence of higher percentage chromium and
molybdenum strengthens the grain boundaries with the formation of complex
metallic carbides, such as M6C and M23C6, and the high cobalt content (19-
21%) strengthens the material by solution hardening, which impedes the
movement of dislocation, thus inducing higher plastic deformation.
Apart from complex carbides, it also contains a large volume of

uniformly distributed ' (Ni3 (Al, Ti)) precipitates (Figure 5.97), the main
strengthening phase in the solution treated condition of the nimonic C-263
material (Ankamma et al 2011). Hence, the shear deformation during the chip
formation of the nimonic C-263 alloy becomes difficult, which ultimately
leads to a work hardening effect. This also enhances the contact pressure at
the cutting edge. This clearly exhibits the response of the nimonic C-263 alloy
while machining. It is evident that the variation in the degree of work
hardening is a function of the process parameters Figure 5.96 (a-c).
283
In general, the degree work hardening reduces with an increase in

the cutting speed, due to the thermal relaxation that occurs because of the
generation of high temperature. However, such relaxation and decrease in
work hardening is not seen from the Figure 5.96 (a-c) while machining the
nimonic C-263 alloy. Since the thermal conductivity of the nimonic C-263
alloy is low compared to that of steels, and the cutting tool is ceramic, there
could be some sluggishness in the conduction of heat. From the illustrations,
the rate of decrease in microhardness, with respect to a depth below the
machined surface increases progressively, when the cutting speed is increased
from 125m/min to 250m/min for the entire feed rate, which clearly indicates
the response of the nimonic material while machining.
The depth of work hardening was almost up to 0.60 mm below the

machined surface while machining at higher machining parameters for a
machining period of 9 minutes. The microhardness of the machined surface
is about 1.35 and 1.8 times the bulk material hardness (320 HV) with respect
to the feed rates of 0.102 mm/rev and 0.143 mm/rev respectively, at a cutting
speed of 125m/min and constant depth of cut 0.75 mm for machining period
of 9 minutes. The increase in the chip contraction associated with the increase
in the feed rate resulted in this increase in microhardness.
The microhardness value on the machined surface was found to be

approximately about 1.5 and 2 times that of the bulk material hardness (320
HV) with respect to feed rates of 0.102 mm/rev and 0.143 mm/rev
respectively, at a cutting speed of 190m/min and constant depth of cut 0.75
mm for machining period of 9 minutes.
The microhardness value on the machined surface was found to be

approximately about 1.7 and 2.15 times that of the bulk material hardness
(320 HV) with respect to the feed rates of 0.102 mm/rev and 0.143 mm/rev
284
respectively, at a cutting speed of 250m/min and constant depth of cut 0.75

mm for machining period of 9 minutes.
It is also observed from Figures 5.96 (a-c) that, the hardness values
increased with increasing feed rate. At a higher feed rate, the load on the
cutting edge increases, thus inducing higher deformation and surface
hardness. Apart from the cutting parameters, the changes in the status of the
cutting edge due to cutting time, viz. tool wear, also inflict alterations in the
machined surface. As seen from the Figure 5.96 (a-c), the level of
microhardness of the machined surface also significantly increases with the
machining time. With an increase in the cutting time, the tool wear
progressively grows, thus inducing higher frictional contact between the tool
and work piece, ultimately leading to pressure induced plastic deformation
rather than shear deformation.
700
S = 0.102 mm/rev, t = 3 min
650
S = 0.102 mm/rev, t = 6 min
600 S = 0.102 mm/rev, t = 9 min
S = 0.143 mm/rev, t = 3 min
550 S = 0.143 mm/rev, t = 6 min
S = 0.143 mm/rev, t = 9 min
500
450
400
350
300
250
0.05 0.15 0.25 0.35 0.45 0.55 0.65
(a) Microhardness variations below the machined surfacce at cutting speed of

125 m/min
285
700
S = 0.102 mm/rev, t = 3 min
650 S = 0.102 mm/rev, t = 6 min
S = 0.102 mm/rev, t = 9 min
600
) S = 0.143 mm/rev, t = 3 min
V 550 S = 0.143 mm/rev, t = 6 min
H
( S = 0.143 mm/rev, t = 9 min
ss 500
e
n
d 450
ra
h
o 400
rc
i 350
M
300
250
0.05 0.15 0.25 0.35 0.45 0.55 0.65
(b) Microhardness variations below the machined surfacce at

Cutting speed of 190 m/min
800
750 S= 0.102 mm/rev, t = 3 min
S= 0.102 mm/rev, t = 6 min
700 S= 0.102 mm/rev, t = 9 min
650 S= 0.143 mm/rev, t = 3 min
600 S= 0.143 mm/rev, t = 6 min
S= 0.143 mm/rev, t = 9 min
550
500
450
400
350
300
250
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
(c) Microhardness variations below the machined surfacce at

Cutting speed of 250 m/min
Figure 5.96 (a-c) MicroHardness Variations Below the Machined
Surface at Different Cutting Speed
286
Figure 5.97 TEM Bright Field Images Showing the M23C6 type Carbides
at the Grain Boundary (Ankamma et al 2011)
5.15.4 Effect of Machining Parameters on Residual Stresses in

Turning Nimonic C-263 alloy Using Whisker Reinforced
Ceramic Insert
In this study, the residual stress measurements were taken three

times at each point on the machined surface, with respect to all cutting
conditions, after finite time intervals of 3 min, 6 min, and 9 min. The typical
residual stress patterns produced in the cutting direction, while turning the
nimonic C-263 alloy in different cutting conditions, using whisker reinforced
ceramic inserts are illustrated in Figures 5.98 - 5.100.
In all the cases, it is found that the residual stresses are more tensile
at the surface of the work piece and become compressive as the depth of the
work piece increases. Then, after approximately 0.6mm depth, the residual
stresses diminish. Nimonic C-263 material has low thermal conductivity
(11.72W/m°C), which is about one third of the whisker reinforced ceramic
cutting material (35.2W/m°C), and therefore, a lot of thermal choking takes
place at the tool work interface, thus resulting in plastic deformation induced
by thermal load (without phase transformation). The external residual stress is
287
tensile, because the surface expands greatly during heating, whereas the
subsurface does not. The external surface is plastified by compression. When
cooling, the external surface tends to recover its position, which is no longer
possible due to the plastic deformation, leading to a tensile state.
As illustrated in Figure 5.98, when the tool is fresh, the maximum

values of the surface tensile residual stresses of about 180MPa and 220MPa
are observed, while turning at the feed rates of 0.102 mm/rev and 0.143
mm/rev respectively, at a cutting speed of 125 m/min and constant depth of
cut 0.75 mm. As the tool wears out, i.e., after cutting for 9 min, the surface
tensile residual stresses rise to about 550MPa and 700MPa, with respect to the
feed rates of 0.102 mm/rev and 0.143mm/rev.
During the exposure to intense heat fluxes near the primary shear
zone and in the rubbing zone, a high temperature gradient exists, which may
lead to the local plastification of the work material. When the surface returns
to a steady state at room temperature, the tensile stresses remain at the
surface. Consequently, the compressive stresses exist in the sub-surface.
Further, the residual stresses near the surface shifted towards compression as
the feed rate is increased, thus indicating the dominance of the mechanical
load (uncut chip thickness). This is observed when the tool is fresh. However,
such an effect is not observed when the tool is used for a period of 9min, thus
diminishing the feed rate effect; instead, the prevalence of the tensile residual
stress is more, which indicates the dominance of the thermal load over
mechanical load.
From illustrations 5.98 and 5.99, it is seen that, as the cutting speed
is increased, the level and depth of the tensile residual stress increases. When
the cutting speed is increased, the temperature increases, thus favouring
thermal load. The maximum values of the surface tensile residual stresses are
about 725MPa and 850MPa, with respect to the feed rate of 0.102 mm/rev
288
and 0.143 mm/rev respectively, for a machining period of 9 minutes, using a

whisker reinforced ceramic insert, at a cutting speed of 250 m/min as shown
in Figure 5.100.
The cutting edge and the rake angle are predominant factors
controlling the distribution of stresses in the subsurface layer. In this study, a
ceramic insert cutting tool having a negative rake (-6°) with ‘T’ land cutting
edge, and 0.8mm nose radius, is used for turning. Generally, the compressive
zone expands visibly when cutting with a rounded cutting edge and larger
negative rake angles. As a consequence, in such cases, the work-hardening
effect will probably be more intense due to the plowing effect. But due to its
lower thermal conductivity of the ceramic insert tool when compared to the
nimonic C-263 alloy, the most of the heat generated is conducted through the
work material, resulting in thermal load. However, the resultant load is
thermal, and hence, higher tensile RS are observed.
Further, it is seen that after operating for a 9 min of cutting time at

a cutting speed of 250m/min, a maximum of 1.13 times tensile residual
stresses is recorded at a cutting speed of 125 m/min. From the analysis of the
residual stresses, in machining the nimonic C-263 alloy, it is observed that the
residual stress values are changed from tensile to compressive, as the depth
beneath the surface decreases, while using a whisker reinforced ceramic
insert. The cutting time and cutting speed have a predominant effect on the
level of the residual stresses. The poor thermal conductivity of the nimonic C-
263 alloy, and the type of cutting tool material have a dominant effect on the
nature of the residual stress produced during machining.
289
800
700 f = 0.102mm/rev, t = 3 min
f = 0.102mm/rev, t = 6 min
600 f = 0.102mm/rev, t = 9 min
500 f = 0.143mm/rev, t = 3 min
f = 0.143mm/rev, t = 6 min
400 f = 0.143mm/rev, t = 9 min
300
200
100
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
-200
-300
-400
-500
1000
900 f = 0.102mm/rev, t = 3 min
800 f = 0.102mm/rev, t = 6 min
f = 0.102mm/rev, t = 9 min
)a 700 f = 0.143mm/rev, t = 3 min
P600 f = 0.143mm/rev, t = 6 min
M
( f = 0.143mm/rev, t = 9 min
se 500
ss 400
er
ts 300
la
u 200
d
is
e 100
R
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
-200
-300
-400

290
1000
900 f = 0.102mm/rev, t = 3 min
800 f = 0.102mm/rev, t = 6 min
f = 0.102mm/rev, t = 9 min
700 f = 0.143mm/rev, t = 3 min
600 f = 0.143mm/rev, t = 6 min
500 f = 0.143mm/rev, t = 9 min
400
300
200
100
0
-100 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
-200
-300
-400

291
5.16 SUMMARY
In this chapter the analysis on turning of nimonic C-263 alloy are

discussed in detail. The discussions are divided into two sections, viz,
(i) Effect of machining parameters on responses in the turning of

nimonic C-263 alloy
The effect of machining parameters in the turning of nimonic

C-263 alloy with respect to different responses such as cutting
force, temperature at tool tip, surface roughness and flank
wear using PVD coated carbide, whisker reinforced ceramic
and cubic boron nitride inserts are discussed.
The tool wear mechanisms in turning nimonic C-263 alloy

with respect to PVD coated carbide, whisker reinforced and
cubic boron nitride inserts are discussed with help of SEM
micrographs.
The on-line tool wear monitoring using Acoustic Emission

(AE) technique during machining of nimonic C-263 alloy with
respect to PVD coated carbide and Whisker reinforced
ceramic inserts are discussed.
(ii) Surface Integrity analysis in machining nimonic C-263 alloy
The effect of machining parameters on surface integrity in

terms of microhardness and residual stresses in turning
nimonic C-263 alloy with respect to PVD coated carbide and
whisker reinforced ceramic inserts are discussed.

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169

RESULTS AND DISCUSSION

The quality and performance of a machined component are directly

In order to maintain and/or improve the reliability of aerospace

5.2 EFFECT OF MACHINING PARAMETERS ON RESPONSES

In this work the effect of machining parameters in the turning of

in chapter 3, Table 3.3 on a nagamati 175 lathe. It is observed that the

5.3 EFFECT OF MACHINING PARAMETERS ON THE

The effect of the machining parameters on the responses such as

5.3.1 Effect of Machining Parameters on the Cutting Force (Fz)

(a) Cutting force at 0.50 mm depth of cut

(b) Cutting force at 0.75 mm depth of cut

(c) Cutting force at 1 mm depth of cut

Figure 5.1 (a-c) Cutting Force Contours in Velocity- Feed Plane at

Figure 5.3 Effect of Feed rate on Cutting Force at Different Cutting

From Figure 5.4, it is observed that the maximum of the cutting

Figure 5.4 Effect of Cutting Speed on Cutting Force at Different

Figure 5.5 Effect of Depth of Cut on Cutting Force at Different Feed

5.3.2 Effect of Machining Parameters on the Cutting Temperature at

(a) Temperature at tool tip at 0.50 mm depth of cut

(b) Temperature at tool tip at 0.75 mm depth of cut

(c) Temperature at tool tip at 1 mm depth of

Figure 5.8 (a-c) 3D Response Surface Plots for the Temperature at

Figure 5.9 Effect of feed rate on temperature at tool tip at different

From Figure 5.10, it is observed that the maximum temperature

From Figure 5.11, it is observed that the temperature tends to

Figure 5.11 Effect of Depth of Cut on Temperature at Tool Tip at

From Figures 5.9-5.11, it is observed that the cutting temperature

5.3.3 Effect of Machining Parameters on the Surface Roughness

(a) Surface roughness at 0.50 mm depth of cut

(b) Surface roughness at 0.75 mm depth of cut

(c) Surface roughness at 1 mm depth of cut

Figure 5.12 (a-c) Surface Roughness Contours in Velocity- Feed Plane at

(b) 3D response surface plots for the surface roughness at 33 m/min

It is found that the surface roughness varies between the range of

As the cutting speed is increased, the conditions promoting the built

Figure 5.14 Effect of Feed rate on Surface Roughness at Different

Figure 5.15 Effect of Cutting Speed on Surface Roughness at Different

0.4 flank wear

From Figure 5.17, it is seen that at a higher depth of cut, a

The SEM micrographs of the machined surface at different

(a) SEM Micrographs of machined (b)SEM Micrographs of machined

(c) SEM Micrographs of machined (d) SEM Micrographs of

Figure 5.18 (a-d) SEM Micrographs of Machined Surface at Different

5.3.4 Effect of Machining Parameters on the Flank Wear Using PVD

(a) Flank wear at 0.50 mm depth of cut

(b) Flank wear at 0.75 mm depth of cut

(c) Flank wear at 1 mm depth of cut

Figure 5.19 (a-c) Flank Wear Contours in Velocity- Feed Plane at

Figure 5.21 Effect of Feed rate on Flank Wear at Different Cutting

Figure 5.22 Effect of Cutting Speed on Flank Wear at Different Depths

At increasing cutting speed and feed rate, the concentration of high

0.2 feed rate = 0.051 mm/rev

During machining, the wear phenomena occur on the tool that

due to the presence of finely dispersed second phase, develops a number of

At higher cutting speed, as observed from the SEM micrograph

(a) V-22m/min, S-0.05mm/rev, ap = 0.50 mm (d) V-54m/min, S-0.143mm/rev, ap = 0.50 mm

Figure 5.24 (a-f) SEM Micrographs of Worn out Cutting Edge at

5.4 COMPARISON OF EXPERIMENTAL RESULTS WITH

The comparison between the experimental results , predicted

The percentage error among the experimental results, predictive

Expt Experimental Values RSM Values

Figures 5.25 (a-b) shows the percentage error between