INVESTIGATION ON TURNING OF STAINLESS

STEEL(GRADE J4) USING CHILLED AIR

MACHINING TECHNIQUE

TEAM MEMBER PROJECT GUIDE

Abhishek Kumar Mr. A.Tamilarasan ,M.Tech.
Ajit Kumar Asst. Prof. / Mech. Engg.
Ashish Kumar
Deep narayan gautam
Dinesh Kumar
 OBJECTIVE

v To get optimum surface roughness value for the turning of Jindal

stainless steel [Grade J4] in term of cutting speed, feed rate
and depth of cut assisted by chilled air cooling technique.
v Machining work carried out using CVD Multi coated carbide tool
under different cutting conditions.
v To indentify tool wear through SEM analysis.
 WORK MATERIAL
v Work material used was stainless steel [Grade J4], family of
stainless steel in the 200-series and these grades are austenitic,
they are not magnetic.

v Good formability and weldablity.

v Excellent toughness (impact resistance) even to very low

cryogenic temperatures – ferrite grades have poor low
temperature toughness.
v The chemical composition of stainless steel Cr-Mn is C
0.115% , Cr 14.69%, Mn 7.97% ,Ni 0.263% etc.
v The acidic nature of the sugar cane juice and toxicity associated
with gaseous product encountered in the manufacture of
sugar, pose a serious challenge to sugar industry.
v Chrome-Manganese austenitic stainless steels are suggested to
keep the performance-cost ratio reasonably economic.
 TOOL MATERIAL

We used TNMG multilayer coated insert. Inserts were coated with

TiN/Al2O3/TiC.

v TiN offers low friction and improved resistance to built-up

edge.
v A TiC coating has high hardness and excellent wear resistance.

v Al2O3 provides a heat barrier with low thermal conductivity

which protect the substrates.

v Coating may be a single-layer or multi-layer and typically 5-20
microns in thickness.
 TOOL INSERT & TOOL HOLDER

TNMG CQ 5525

Tool holder
MTJNR 2525 M16
 RECENT COOLING TECHNIQUE LUBRICATION

v High pressure lubrication (HPL)

v Minimum quantity lubricant (MQL)
v Steam cooling
v Solid coolant
v Chilled Air Assisted machining technique
COLD AIR GUN
 HOW VORTEX TUBE WORKS

vCompressed air are injected tangentially into the vortex tube

through the nozzle.
vAccelerated to a high rate of rotation of about 1,000,000 rpm.
vAir stream moves towards the hot end where some air escapes
through the control valve.
vRemaining air is forced backed through the centre of the vortex
tube losing their kinetic energy.
 EXPERIMENTAL METHODOLOGY
An experimental of prior experimental studies, a methodology
was developed to study the surface roughness of the machined
part in turning.

CUTTING CONDITIONS

v Cutting tests were carried out on the medium duty lathe machine
under chilled air assisted condition.

v The tools were tested under a various spindle speed of 208, 310,
320 RPM.

v The feed rate used was varied from 0.07mm/rev to 0.2mm/rev.

v The depth of cut varies from 0.1mm to 0.5mm.

 EXPERIMENTAL DETAILS
Sl. no. Cutting speed Feed rate Depthof cut Ra (micron)
(Vs) m/min. (f) mm/rev. (mm)
1. 20.91 0.07 0.1 1.00
2. 20.91 0.09 0.3 1.61
3. 20.91 0.2 0.5 3.46
4. 31.16 0.07 0.3 1.23
5. 31.16 0.09 0.5 1.91
6. 31.16 0.2 0.1 2.13
7. 32.16 0.07 0.5 1.37
8. 32.16 0.09 0.1 0.94
9. 32.16 0.2 0.3 2.14
 EXP . NO : 02 EXP . NO : 03

EXP . NO : 04 EXP . NO : 05
EXP . NO : 06

NO : 07 EXP . NO : 08
 RESULT AND DISCUSSION
The experimental results were analysed using analysis of
variance(ANOVA) for identifying the significant factors affecting the
performance measures.
Residual for Ra
 
 
Source DF Seq SS Adj SS Adj MS F P
_______________________________________________________________________________
Vc 2 0.43742 0.43742 0.21871 6.45 0.134
F 2 3.16549 3.16549 1.58274 46.67 0.021
DOC 2 1.22829 1.22829 0.61414 18.11 0.052
Error 2 0.06782 0.06782 0.03391
_______________________________________________________________________________
Total 8 4.89902
_______________________________________________________________________________

S = 0.184150 R-Sq = 98.62% R-Sq(adj) = 94.46%

v The total variation is the sum of variation due to various
controlled factors , their interactions and variation due to
experimental error.
v Effect of feed is important as the statistical significant values less
than α (0.05)value at 98.62% confidence level.
v R- sq represent the regression confidence larger values of R-sq is

always desirable.
v The R –sq values are 98.62% which shows the high correlation
that exits between the experimental values and predicated values.
 Main Effects Plot for Means
Data Means
VC F
2.5

2.0

1.5
Mean of Means

1.0
20.91 31.16 32.16 0.07 0.09 0.20
DOC
2.5

2.0

1.5

1.0
0.1 0.3 0.5

Fig 2 main effect plot for means

RESPONSE TABLE FOR SIGNAL TO NOISE
RATIOS “SMALLER IS BETTER”

LEVEL1 Vc F DOC

1 -4.973 -1.511 -2.010

2 -4.662 -3.073 -4.181

3 -2.935 -7.986 -6.379

DELTA 2.038 6.475 4.369

RANK 3 1 2
 RESPONSE TABLE FOR MEANS

LEVEL1 Vc F DOC

1 2.023 1.200 1.357

2 1.757 1.487 1.660

3 1.483 2.577 2.247

DELTA 0.540 1.377 0.890

RANK 3 1 2
v The response table show the average of response characteristic at
each level and factor.
v Rank is based on delta statistics ,compare the relative magnitude
of effects.
v The delta statistics is the highest minus the lowest average of
each factor.
v From means the response ,cutting speed 32.16m/min, 0.07mm/rev
feed and 0.1mm depth of cut good for surface finish.
EFFECT OF CUTTING SPEED DURING
MACHINING
EFFECT OF FEED RATE DURING
MACHINING
 SEM ANALYSIS
v Dominant wear was observed at early stage of cutting .

v Discrete micro-chipping of the cutting edge is observed at low

cutting speed .
v Flank wear occurs on the relief face of the cutting tool.

v The flank wear is characterized by the abrasive grooves and

ridges on the flank face.

v Crater wear occur on the rake face of the tool.
Flank Wear

Crater Wear
 CONCLUSION
v Feed rate provide the primary contribution on surface roughness.
v Depth of cut is less significant.
v Application of chilled cold air give the best result of surface finish.
v At 32.16m/min spindle speed, 0.07 mm/rev feed rate and 0.1mm
depth of cut gives the best result of surface finish.
THANK YOU