Investigation phenomena of flank wear at initial stage during cutting process of stainless steel 304

Chandran, Devaagar (2016) Investigation phenomena of flank wear at initial stage during cutting process of stainless steel 304. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

304 Stainless Steel is a chromium-nickel based steel alloy that is widely used in petrochemical industries and relatively known as difficult to be machined material due to its high work hardening and built up edge (BUE). The flank wear rate of the cutting tool is affected due to its drawbacks properties which resulting in the deformation of cutting tool geometry. To understand this condition, this research is conducted to meet the following objectives; to investigate flank wear rate at initial stage within specified cutting parameter range, to identify the effect of cutting parameter on the wear rate and to determine and validate the optimum process parameter that gives lowest wear rate. Response Surface Methodology (RSM) through Historical Data is used to analyse the relationship between the cutting parameters with cutting tool wear. A total 9 number of experiments are carried out. The selected machining parameters were Vc m/min = 80, 110 and 140, Fz mm/rev = 0.10, 0.15 and 0.2 and fixed ap = 0.2 mm. Tungsten carbide coated with TiAlN is used as cutting tool in this research. Formation of flank wear is measured and observed by using toolmaker microscope and stereo microscope. Referring the results, indicates that the feed rate influence the rapid flank wear rate. As the feed rate increase, the wear rate increases. Optimum cutting parameter Vc m/min = 80, fz mm/rev = 0.10 and ap = 0.2mm is generated by using ANOVA and validate by test machining. Error percentage between actual and predicted flank wear rate is 7.70%.

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