International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 01, January 2019, pp. 1862-1873, Article ID: IJMET_10_01_184
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=1
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
Scopus Indexed
INVESTIGATION OF WEAR BEHAVIOUR OF
SILICON CARBIDE TOOL INSERTS AND
TITANIUM NITRIDE COATED TOOL INSERTS
IN MACHINING OF EN8 STEEL
STEEL
S.Ganeshkumar
Asst Professor – Sri Eshwar College of Engineering, Coimbatore, Tamilnadu
Dr.V.Thirunavukkarasu
Principal and Professor, Sri Balaji chokkalingam Engineering college, Arni. Tamilnadu
Dr.R.Sureshkumar
Professor – Sri Eshwar college of Engineering, Coimbatore, Tamilnadu
Dr.S.Venkatesh
Assistant Professor – Sri Eshwar college of Engineering, Coimbatore , Tamilnadu
Dr.T.Ramakrishnan
Assistant Professor – Sri Eshwar college of Engineering, Coimbatore , Tamilnadu
ABSTRACT
The machining process is essential in the manufacturing industry. Among the all
machining process, turning is the broadest techniques used to remove the metal. In
this machining process, metal removal rate was influenced by the sharpness of the
cutting tools. Due to the friction between the workpiece and the tool insert, tool wear
occurs. After the wear takes place, the efficiency of the machine will be reduced and
metal removal time will be increased. Hence, it is essential to investigate the
behaviour of the tool wear under the machining. This investigation is to analyse the
wear characteristics of the tool inserts. The machining of the EN8 was examined in
this research using silicon carbide tool inserts and Titanium nitride coated tool
inserts. This research was investigated the wear behaviour of the silicon carbide tool
insert, and titanium nitride tool insert in machining of EN8 steel using a horizontal
machining centre. The wear of the inserts was measured using toolmakers
microscope. The flank wear and crater wear was considered in the tool wear
measurement.
Keywords: Flank wear, Crater wear, EN8 steels, Titanium nitride, silicon carbide.
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S.Ganeshkumar, Dr.V.Thirunavukkarasu, Dr.R.Sureshkumar, Dr.S.Venkatesh and
Dr.T.Ramakrishnan
Cite this Article: S.Ganeshkumar, Dr.V.Thirunavukkarasu, Dr.R.Sureshkumar,
Dr.S.Venkatesh and Dr.T.Ramakrishnan, Investigation of Wear Behaviour of Silicon
Carbide Tool Inserts and Titanium Nitride Coated Tool Inserts in Machining of En8
Steel, International Journal of Mechanical Engineering and Technology, 10(1), 2019,
pp. 1862-1873.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=1
1. INTRODUCTION
On the outset, in several manufacturing industries, the quality of the components plays a
significant role in satisfying the engineering needs. Precision and accuracy of components can
be attained only by machining with appropriate machine tools and machining conditions. In
engineering, steels are majorly used in automotive, aerospace and other industrial
applications. In general machining processes for instance drilling, turning, tapping, reaming
and hobbing are being used in manufacturing processes. Turning is an effective operation
among all the machining operations. After the machining process, worn out tools are replaced.
In conventional lathe machines, instead of replacing the whole tool setup, to reduce the
replacement cost, inserts are being used for replacement. In this, tool inserts are being used to
remove metals and worn out tool inserts are replaced by new insert. In the manufacturing of
components, tool wear monitoring is essential, and it is the most challenging one to the
manufacturing industry to meet precision and accuracy. To improve the tool life, inserts were
coated with harder materials to achieve the better performance.Coated tool inserts increase
tool life by increasing toughness, resistance to abrasion, resistance to thermal deformations,
modulus of elasticity and wear resistance, which results in achieving precision and accuracy
in machining components. Also, these coated tool inserts broaden the range of depth of cut,
cutting speed, other machining parameters and reduce the time of machining. Coating of tool
inserts gives longer tool life, higher cutting parameters leading to reliable performance while
machining. The coating process applies to turning, milling, drilling, tapping, dry cutting
operations with or without lubrication.
2. LITERATURE REVIEW
Naskar et al. exhibited the performance of tool inserts with coatings in the quick dry turning
of carbon steels. In these investigations, tool inserts were coated by Al2O3 and Titanium
nitride by chemical vapour deposition. In this experimentation, Ti-CN and Titanium carbide
was coated using the physical vapour deposition. Bilayer coatings of these two materials were
involved in machining operation of C 20 and C 80 Steels. From this investigation, Flank wear
was studied at the feed rate of 300m/min and 600m/min. It was observed that flank wear
varies severely concerning the coating materials. Also, it exhibits the plastic deformation
induced in inserts and leads to flank wear mechanism. These experimental results furnish a
new flank wear model for inserts coated with Al2O3 material, and it was concluded that wear
phenomena depend on the cutting speed and material of the workpiece.
Paiva.D et al. depicted the frictional wear performance of hard coatings in machining of
super duplex stainless steel. This research involved in machining of super duplex stainless
steel with cemented carbide tool inserts coated with TiCN+Al2O3 as a bilayer chemical
vapour deposition coating and Ti-CN and Al-Ti-N bilayer physical vapour deposition coating
technique. Two coated tool inserts were employed in machining of super duplex stainless
steel, and machining performances were studied to compare the PVD and CVD coating
techniques. This research concluded that surface finish was improved in physical vapour
deposition methods compared with chemical vapour deposition methods.
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Investigation of Wear Behaviour of Silicon Carbide Tool Inserts and Titanium Nitride
Coated Tool Inserts in Machining of En8 Steel
Saketi et al. carried out the investigation on surface topography on the development of
craterwear by layers in the orthogonal turning of 316 L Austenitic stainless steel.
Experimentation was conducted with tool inserts coated with (Ti+Al) N and, (Al, Cr)2O3 by
physical vapour deposition methods and Ti(C, N)-Al2O3 – TiN by chemical vapour
deposition methods with cemented carbide tool inserts. These investigations focused only on
surface topography, and hence the surface topography was taken by scanning electron
microscopy at the post machining operation. Results depict that transfer of tool material to
workpiece occurs during the machining process, and it results in surface topography of the
tool inserts. These phenomena of adhesion of tool insert particles with the workpiece lead to
crater wear, and it leads to varying the surface roughness topography severely.
3. TAGUCHI DESIGN OF EXPERIMENTS
The Feed rate, Depth of cut and Spindle speed were considered, and responses were crater
wear, before executing the experiments, the number of trials should be formulated by using
the design of Experiments. In Taguchi algorithm, Number of parameters and Number of
Ranges were given as input as shown in table 3.1
Table 3.1
Parameter
Feed
Depth of
rate
cut
mm/min
mm
0.7
0.5
250
0.8
0.75
500
0.9
1
750
1
1.25
1000
1.1
1.5
1250
Range
Speed
rpm
4. EXPERIMENTAL SETUP
The experiment was done in horizontal turning centre lathe machine. The 50.8 mm (2 inches)
diameter of the EN8 cylindrical workpiece was held in the three-jaw chuck. The Feed rate,
spindle speed and depth of cut were given based on the results obtained from the design of
experiments. The speed of the spindle was given using the gearbox and machining was done
with silicon carbide uncoated tool inserts. After machining was completed, the uncoated insert
was replaced by titanium nitride coated tool insert. For the 25 number combinations of
machining parameters, the machining process was done for coated and uncoated tool inserts.
Whenever the tool insert undergoes machining process, wear occurs. The wear of the tool
insert was found using the tool maker’s microscope.
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Dr.T.Ramakrishnan
No. of Trials
Table 4.1 Crater and flank wear of uncoated and coated tool inserts
Uncoated
Coated
inserts
inserts
Crater Flank Crater Flank
Wear
wear
Wear
wear
mm
mm
mm
mm
1
0.21
0.33
0.19
0.3
2
0.33
0.49
0.32
0.46
3
0.36
0.6
0.3
0.51
4
0.42
0.64
0.4
0.63
5
0.52
0.71
0.47
0.72
6
0.28
0.54
0.24
0.49
7
0.37
0.65
0.35
0.63
8
0.43
0.7
0.41
0.64
9
0.5
0.75
0.45
0.7
10
0.63
0.82
0.58
0.81
11
0.42
0.68
0.36
0.63
12
0.51
0.76
0.44
0.74
13
0.58
0.83
0.5
0.81
14
0.64
0.89
0.58
0.87
15
0.71
0.98
0.71
0.95
16
0.52
0.83
0.46
0.79
17
0.63
0.92
0.59
0.91
18
0.65
0.97
0.61
0.93
19
0.74
1.01
0.64
0.97
20
0.8
1.11
0.76
1.1
21
0.62
0.95
0.57
0.92
22
0.69
1.1
0.68
1.04
23
0.74
1.12
0.74
1.12
24
0.8
1.18
0.75
1.11
25
0.93
1.28
0.83
1.23
The flank wear and crater wear were measured using tool makers microscope. The tool
insert was placed on the measuring table and it was illuminated using two LEDs. the
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Investigation of Wear Behaviour of Silicon Carbide Tool Inserts and Titanium Nitride
Coated Tool Inserts in Machining of En8 Steel
magnification was done using a lens and the distance was measured using micrometers. While
placing the tool insert on the measuring table, the image of the insert was visible in the
eyepiece of the microscope. The eyepiece carries a cross hair for the reference and the table
can be translated to X and Y axes by the two micrometer screws as shown in figure 4.1 The
Tool makers microscope was shown in the figure 4.2. The difference in
Figure 4.1 Tool maker’s microscope measuring of flank wear
the geometry of the tool insert was observed using the micrometer screws. The tool insert
was placed horizontally to measure the flank wear and it was placed vertically to measure the
crater wear. The geometrical change was inferred for all tool inserts. The identification marks
were given to all the tool inserts for the 25 trials of coated and uncoated tool inserts. these
tools insert geometry was identified using the tool makers microscope
Figure 4.2 Tool maker’s microscope
5. RESULTS AND DISCUSSION
In machining process, wear of tool inserts plays a significant role in tool wear. Crater wear
and flank wear were considered in experimentation. From the experimental results, at the feed
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Dr.T.Ramakrishnan
rate of 1.1 mm/min, depth of cut of 1.5 mm and spindle speed of 1000rpm, 0.83 mm of crater
wear and 1.23 mm of flank wear were obtained for coated tool inserts. It was observed that,
this feed rate, depth of cut and spindle speed were maximum. The contribution of flank wear
and crater wear in tool geometry reduction
Crater wear of tool inserts varies corresponding to the depth of cut, spindle speed and feed
rate. From experiment results, at a feed rate of 1.1 mm/min, depth of cut of 1.5 and speed of
1000 rpm, 0.93 mm of crater wear was found for uncoated tool inserts whereas, in TiN coated
inserts, crater wear was reduced to 0.83 mm for same operating conditions. From the
observations of all experimental trials with the EN8 steel rod, crater wear was found less in
TiN coated tool inserts compared with the uncoated tool inserts. The correlations derived by
mathematical modelling for uncoated silicon carbide is given by Crater wear = - 0.637 +
1.00 Feed rate + 0.292 Depth of cut + 0.000006 Speed. From the regression equation, it was
concluded that the significant predictors of the crater wear are the depth of cut and feed rate.
For coated tool inserts, mathematical model correlated with machining parameters are given
by Crater wear = - 0.615 + 0.962 Feed rate + 0.280 Depth of cut - 0.000018 Speed. At the
feed rate of 1.1 mm/min, 1.5 mm depth of cut and spindle speed of 1000 rpm, it was found
that the coated tool inserts have undergone maximum wear of 0.83 mm, and uncoated
siliconcarbide inserts undergone the maximum of 0.93 mm of wear. The behaviour of crater
wear for TiN coated inserts and uncoated silicon carbide tool inserts were depicted in figure
5.1. At the feed rate of 0.7 mm/ min, 0.5 mm depth of cut and spindle speed of 250 rpm, 0.21
mm crater wear was found in uncoated silicon carbide tool inserts, with the same operating
conditions, 0.19 mm crater wear was found in titanium nitride coated tool inserts.
Figure 5.1
It was observed that 0.02 mm crater wear was reduced in coated tool inserts. Similarly, the
behaviour of crater wear was compared with all ranges of speed, depth of cut and feed rate. At
a maximum feed rate of 1.1 mm/min, crater wear was found the peak value for both coated
and uncoated tool inserts. From these results, it was concluded that feed rate plays the critical
role and majorly contributes to crater wear. From experimental results, it was found that, in
machining of EN8 steel by uncoated and coated inserts, at the feed rate of 0.9mm/min, 1mm
depth of cut, 1250 rpm spindle speed , crater wear of 0.58 mm was found in uncoated SiC
inserts and for titanium nitride coated tool inserts, 0.5 mm of crater wear was found. Among
the 25 number of trials, these combinations furnish the maximum reduction of tool wear.
Hence it was shown that the feed rate of 0.9mm/min, 1mm depth of cut, 1250 rpm spindle
speed are optimum to machine EN8 steels with TIN coated tool inserts.The variation of crater
wear pattern in uncoated and coated tool inserts at the constant feed rate of 0.7 mm/min, 0.8
mm/min, 0.9 mm/min, 1.0 mm/min and 1.1 mm/min were shown in figure 8.5, 8.6, 8.7, 8.8
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Investigation of Wear Behaviour of Silicon Carbide Tool Inserts and Titanium Nitride
Coated Tool Inserts in Machining of En8 Steel
and 8.9. The optimum region was shown in these plots to achieve less wear in coated tool
inserts. It was found that 1 mm/min depth of cut with 0.7mm feed rate wear was minimum in
coated tool inserts. Similarly, at 0.8 mm/min feed rate, crater wear was minimum at 1.2 mm
and 1.4 mm of the depth of cut. The region of crater wear reduction was plotted in 5.2. the
minimum wear zone was demonstrated for 0.9mm/min, 1mm/min and 1.1mm/min in
5.3,5.4,5.5 and 5.6 respectively.
Figure 5.2
Figure 5.3
Figure 5.4
The results exhibited that the flank wear was reduced in coated tool inserts compared with
coated tool inserts. For feed rate f = 0.7 mm/ min, depth of cut of 0.5 mm and spindle speed of
250 rpm, 0.33 mm flank wear occurred in uncoated silicon carbide tool inserts whereas, in
titanium nitride coated tool inserts, flank wear was reduced to 0.30. For all combination of
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S.Ganeshkumar, Dr.V.Thirunavukkarasu, Dr.R.Sureshkumar, Dr.S.Venkatesh and
Dr.T.Ramakrishnan
process parameters, the behaviour of flank wear was shown in figure 5.7. At the feed rate of
0.7mm/ min, depth of cut 1mm, and spindle speed of 150 rpm, flank wear for uncoated tool
insert was 0.6 mm and for Titanium nitride coated silicon carbide tool inserts 0.51 mm has
occurred. It was found that 0.09mm of wear was reduced after coating of TiN.
Figure 5.5
Figure 5.6
The Metal removal rate was maximum at higher spindle speed. Hence the machining with
the speed of 1000 rpm, the feed rate of 0.8mm/ min, depth of cut 1mm, flank wear was
reduced. Correlating all the observations from the experiments, the behaviour of flank wear
varies concerning the depth of cut, feed rate and, spindle speed. The following mathematical
equation has depicted the behaviour of flank wear, uncoated and coated tool inserts as follows
For uncoated tool inserts
Flank wear = - 0.748 + 1.42 Feed rate + 0.295 Depth of cut + 0.000013 Speed
For uncoated tool inserts
Flank wear = - 0.789 + 1.41 Feed rate + 0.309 Depth of cut + 0.000021 Speed
The mathematical equation exhibits the contribution of machining parameters. It was
inferred that for both uncoated and coated tool inserts, feed rate, plays the critical role in flank
wear. The depth of cut played second largest contributor of flank wear. In addition to the
behaviour of flank wear, it was observed that in uncoated silicon carbide insert and titanium
nitride coated inserts flank wear plays the significant role in the reduction of tool geometry
since the friction between the tool insert and workpiece acts on the contact surface (Nose
radius). Hence flank wear was high in all trials, at the feed rate of 1.1mm/min, depth of cut
0.75mm and spindle speed of 250 rpm, 0.69 mm crater wear and 1.1 mm of flank wear was
found.it was the maximum difference observed between the crater wear and flank wear.
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Investigation of Wear Behaviour of Silicon Carbide Tool Inserts and Titanium Nitride
Coated Tool Inserts in Machining of En8 Steel
Figure 5.7
Figure 5.8
Figure 5.9
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S.Ganeshkumar, Dr.V.Thirunavukkarasu, Dr.R.Sureshkumar, Dr.S.Venkatesh and
Dr.T.Ramakrishnan
Figure 5.10
Figure 5.11
Figure 5.12
The deviation between the experimental and theoretical flank wear was obtained.in flank
wear regression equations. The feed rate of 0.75 mm/min, depth of cut of 0.25 mm, and
spindle speed of 300 rpm, 0.39mm of flank wear were found, whereas 0.33 mm of flank wear
was observed in experiments with the same operating conditions. The flank wear for uncoated
silicon carbide tool inserts deviates 16% between actual and theoretical flank wear. Variation
of flank wear pattern with depth of cut: The variation of flank wear pattern in uncoated and
coated tool inserts at constant feed rate of 0.7 mm/min, 0.8 mm/ min, 0.9 mm/min, 1.0
mm/min and 1.1 mm/min were shown in figure 5.8,5.9,5.10,5.11 and 5.12. It was found that
the 1 mm depth of cut, 0.7 mm/min feed rate, the difference between 0.8 mm to 1.2 mm.
Similarly, for 0.8 mm/min, 0.9 mm/min, 1.0 mm/min and 1.1 mm/min the deviation of flank
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Investigation of Wear Behaviour of Silicon Carbide Tool Inserts and Titanium Nitride
Coated Tool Inserts in Machining of En8 Steel
wear in uncoated tool inserts and uncoated tool inserts were depicted in plots. At feed rate, 1.1
mm/min, the maximum reduction of flank wear was found in TiN coated tool inserts.
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