Analytical and experimental investigation of effects of high-pressure coolant on tool wear, tool life and surface roughness in turning steel

Abstract

Manufacturing quality products at a higher rate and low cost is the key to exist and sustain in the modem era of cut-throat competition. To do that, , machining is practised at extreme conditions. As part of this approach, high speed machining is adopted. However, high speed machining is inherently associated with generation of intense heat and cutting temperature at the cutting zone resulting increased tool wear and deterioration of machined surface. New methods are being explored to reduce the heal. Application of high-pressure coolant is perceived to be a superior choice in this regard. Technological beneficial effects of proper high-pressure coolant on machining already been established in number of previous investigations Surface roughness is a determinant of product quality and reduction of tool wear and consequent increase of toollne can reduce the machining cost .• However, estimation of these two machining performance parameters can contribute to manufacturing optimization and planning. Mathematicai models are instrumental to predict machining performance at different machining combinations, Response surface method is adopted to develop statistical models of tool life and surface roughness. Cutting speed and feed rate are the independent variables of the models. As part of this method, based on the experimental results of turning medium carbon steel statistically designed speed-feed combination by uncoated carbide insert using high-pressure coolant jet, regression analysis will be performed to determine the coefficients of the model followed by analysis of variance to check the adequacy of the model.The models are expected to quantify machining performance in terms oftoollife and surface roughness at various cutting speed and feed.