EXPERIMENTAL INVESTIGATION AND PROCESS PARAMETER

OPTIMIZATION OF EN31 STEEL WITH CHROMIUM COATED DRILL

BITS USING ANOVA
ABSTRACT
The metal cutting is very essential to try for high metal removing rate and
the best product quality. The major problem in achieving high productivity and best quality is
short life span of a tool. To enhance the life of tool many new materials are developed so has to
meet the market demand and competitive price for this there should be proper control over
various cost involved in machining named as material cost labour cost and tooling cost the
material cost can be controlled by using special material which meet all required properties with
reduced price.

The methodology of Modified Taguchi optimization method for simultaneous

minimization and maximization of Surface roughness (Ra), machining time and material removal
rate of EN31 Alloy steel affect the aesthetical aspect of the final product and hence it is essential
to select the best combination values of the CNC drilling process parameters to minimize as well
as maximize the responses. The experiments were carried out by a CNC lathe, using physical
vapour deposition coated Chromium nitride drilling tool bit for the machining of EN19. The
experiments were carried out as per L9 orthogonal array with each experiment performed under
different conditions of such as speed, type of drilling tool, and feed rate. The Taugchi method and
analysis of variance (ANOVA) was employed by using MINITAB-15 software to identify the
level of importance of the machining parameters on Surface roughness (Ra), Machining time and
Material Removal Rate (MRR).

CHAPTER-1
1 INTRODUCTION
Drilling is one of the basic machining process of making holes and it is essentially for
manufacturing industry like automobile industry, medical industry, and aerospace industry.
Especially drilling is necessary in industries for assembly related to mechanical fasteners. It is
reported that around 55,000 holes are drilled as a complete single unit production of the AIR
BUS A350 aircraft (3) Drilling of metals is increasing requirements for producing small products
and more highly functional. With increasing demand for precise component production, the
important of drilling processes is increasing rapidly. Because of the requirement of deeper and
smaller holes required in the above said industries. It is required for drilling process technologies
to achieve higher accuracy and higher productivity. There are several convectional and nonconventional manufacturing process by which drilling can be possible. Drilling using laser beam,
electrons beam and electric discharge methods and also electrolytic polishing, electro chemical
machining has been frequently used by industries and for experimental researches. However, for
general application, conventional drilling process is preferred due to the higher economical
benefits than other processes and also it has highly productivity than other non -convectional
drilling processes. Physical vapour deposition ( PVD ) describes a variety of vacuum deposition
methods used to deposit thin films by the condensation of a vaporized form of the desired film
material onto various work piece surfaces (e.g., onto semiconductor wafers). The coating method
involves purely physical processes such as high-temperature vacuum evaporation with
subsequent condensation, or plasma sputter bombardment rather than involving a chemical
reaction at the surface to be coated as in chemical vapour deposition.
EN31 is an important material with desirable properties, including high resisting in nature
against wear and can be used for components which are subjected to severe abrasion, wear, high
surface loading. Hence, EN31promises fruitful development for applications in the automobile
sector due to its high strength.

1.1 CNC LATHE

Computer numerical controlled (CNC) lathes are rapidly replacing the older production
lathes (multi spindle, etc.) due to their ease of setting, operation, repeatability and accuracy. They
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are designed to use modern carbide tooling and fully use modern processes. The part may be
designed and the tool paths programmed by the CAD/CAM process or manually by the
programmer and the resulting file uploaded to the machine, and once set and trailed the machine
will continue to turn out parts under the occasional supervision of an operator

Figure (1.1) CNC machine

The machine is controlled electronically via a computer menu style interface; the
program may be modified and displayed at the machine, along with a simulated view of the
process. The setter/operator needs a high level of skill to perform the process, however the
knowledge base is broader compared to the older production machines where intimate
knowledge of each machine was considered essential. These machines are often set and operated
by the same person, where the operator will supervise a small number of machines (cell).
The design of a CNC lathe varies with different manufacturers, but they all have some
common elements. The turret holds the tool holders and indexes them as needed, the spindle
holds the work piece and there are slides that let the turret move in multiple axes simultaneously.
The machines are often totally enclosed, due in large part to occupational health and safety
(OH&S) issues. With rapid growth in this industry, different CNC lathe manufacturers use
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different user interfaces which sometimes make it difficult for operators as they have to be
acquainted with them. With the advent of cheap computers, free operating systems such as
Linux, and open source CNC software, the entry price of CNC machines has plummeted.
1.1.1 LATHE OPERATIONS
In order to perform different operations in a lathe, the work piece may be supported and
driven by any one of the following methods :
1. Held between centres and driven by carriers and clutch plates.
2. Held on a mandrel which is supported between centers and driven by a carriers and catch
plates.
3. Held and driven by chuck with the other end supported on the tailstock centre.
4. Held and driven by a chuck or a faceplate or an angle plate.
The above methods of holding the work may be broadly classified under two headings :
1. Work piece held between centres,
2. Work piece held by a chuck or any other or any other fixture.
1.1.2 BASIC LATHE OPERATIONS
1. Drilling
2. Turning
3. Threading
4. Chamfering
5. Knurling
6. Grooving
7. Spinning
8. Boring
9. Tapping
10. Facing

1.1.2.1 DRILLING
Drilling in a lathe is to remove material from the work piece to produce a cone-shaped or
a cylindrical hollow surface.
1.1.2.2 DRILLING PROCESS
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular crosssection in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed
against the work piece and rotated at rates from hundreds to thousands of revolutions per minute.
This forces the cutting edge against the work piece, cutting off chips (swarf) from the hole as it is
drilled.

1.1.2.3 TYPES OF DRILLING PROCESS

1. Spot drilling
2. Center drilling
3. Deep hole drilling
a. Gun drilling
b. Trepanning
4. Micro drilling
5. Vibration Drilling

1.1.2.3.1 SPOT DRILLING

The purpose of spot drilling is to drill a hole that will act as a guide for drilling the
final hole. The hole is only drilled part way into the work piece because it is only used to guide
the beginning of the next drilling process.
1.1.2.3.2 CENTER DRILLING
The purpose of center drilling is to drill a hole that will act as a center of rotation for
possible following operations. Center drilling is typically performed using a drill with a special
shape, known as a center drill.
1.1.2.3.3 DEEP HOLE DRILLING
Deep hole drilling is defined as a hole depth greater than ten times the diameter of the
hole. These types of holes require special equipment to maintain the straightness and tolerances.
Other considerations are roundness and surface finish.

1.1.2.3.4 GUN DRILLING

Another type of drilling operation is called gun drilling. This method was originally
developed to drill out gun barrels and is used commonly for drilling smaller diameter deep holes.
This depth-to-diameter ratio can be even more than 300:1. The key feature of gun drilling is that
the bits are self-centering; this is what allows for such deep accurate holes. The bits use a rotary
motion similar to a twist drill; however, the bits are designed with bearing pads that slide along
the surface of the hole keeping the drill bit on center. Gun drilling is usually done at high speeds
and low feed rates.
1.1.2.3.5 TREPANNING
Trepanning is commonly used for creating larger diameter holes (up to 915 mm
(36.0 in)) where a standard drill bit is not feasible or economical. Trepanning removes the
desired diameter by cutting out a solid disk similar to the workings of a drafting compass.
Trepanning is performed on flat products such as sheet metal, granite (curling stone), plates, or
structural members like I-beams.
1.1.2.3 .6 MICRO DRILLING
Micro drilling refers to the drilling of holes less than 0.5 mm (0.020 in). Drilling of holes
at this small diameter presents greater problems since coolant fed drills cannot be used and high
spindle speeds are required. High spindle speeds that exceed 10,000 RPM also require the use of
balanced tool holders.
1.1.2.3.7 VIBRATION DRILLING
The first works on vibration drilling began in the 1950s (Pr. V.N. Poduraev, Moscow
Bauman University). The main principle consists in generating axial vibrations or oscillations in
addition to the feed movement of the drill so that chips could be fractionated and easily removed
from the cutting zone.
1.2 PHYSICAL VAPOUR DEPOSITION (PVD)
Physical vapour deposition ( PVD ) describes a variety of vacuum deposition methods
used to deposit thin films by the condensation of a vapourized form of the desired film material
onto various work piece surfaces (e.g., onto semiconductor wafers). The coating method involves
purely physical processes such as high-temperature vacuum evaporation with subsequent
condensation, or plasma sputter bombardment rather than involving a chemical reaction at the
surface to be coated as in chemical vapour deposition.
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1.2.1 TYPES OF PVD COATING

1. Cathodic arc deposition
2. Electron beam physical vapour deposition
3. Evaporative deposition
1.2.1.1 CATHODIC ARC DEPOSITION.
In which a high- power electric arc discharged at the target (source) material
blasts away some into highly ionized vapour to be deposited onto the work piece
1.2.1.2 ELECTRON BEAM PHYSICAL VAPOUR DEPOSITION
In which the material to be deposited is heated to a high vapour pressure by electron
bombardment in "high" vacuum and is transported by diffusion to be deposited by condensation
on the (cooler) work piece.
1.2.1.3 EVAPOURATIVE DEPOSITION
In which the material to be deposited is heated to a high vapour pressure by electrically
resistive heating in "low" vacuum. Pulsed laser deposition: In which a high- power laser ablates
material from the target into a vapour.
1.2.1.4 SPUTTER DEPOSITION
In which a glow plasma discharge (usually localized around the "target" by a magnet)
bombards the material sputtering some away as a vapour for subsequent deposition
1.2.2 USES 0F PHYSICAL VAPOUR DEPOSITION.
PVD is used in the manufacture of items, including semiconductor devices , aluminized PET
film for balloons and snack bags, and coated cutting tools for metalworking. Besides PVD tools
for fabrication, special smaller tools (mainly for scientific purposes) have been developed. They
mainly serve the purpose of extreme thin films like atomic layers and are used mostly for small
substrates. A good example is mini e-beam evaporators which can deposit monolayers of
virtually all materials with melting points up to 3500 C. Common coatings applied by PVD are
Titanium nitride, Zirconium nitride, Chromium nitride, Titanium aluminum nitride. [3] The
7

source material is unavoidably also deposited on most other surfaces interior to the vacuum
chamber, including the fixturing to hold the parts.
1.2.3 TESTING PVD
Some of the techniques used to measure the physical properties of PVD coatings
are: Calo tester: coating thickness test Nanoindentation: hardness test for thin-film coatings Pin
on disc tester: wear and friction coefficient test Scratch tester: coating adhesion test
1.2.4 ADVANTAGES
PVD coatings are sometimes harder and more corrosion resistant than coatings
applied by the electroplating process. Most coatings have high temperature and good impact
strength, excellent abrasion resistance and are so durable that protective topcoats are almost
never necessary. Ability to utilize virtually any type of inorganic and some organic coating
materials on an equally diverse group of substrates and surfaces using a wide variety of finishes.
More environmentally friendly than traditional coating processes such as electroplating and
painting.
1.2.5 DISADVANTAGES
Specific technologies can impose constraints; for example, line-of-sight transfer is
typical of most PVD coating techniques, however there are methods that allow full coverage of
complex geometries. Some PVD technologies typically operate at very high temperatures and
vacuums, requiring special attention by operating personnel.
1.2.6 APPLICATION
PVD coatings are generally used to improve hardness, wear resistance and oxidation
resistance. Thus, such coatings use in a wide range of applications such as: Aerospace
Automotive Surgical/Medical Dies and moulds for all manner of material processing Cutting
tools Firearms Optics Watches Thin films (window tint, food packaging, etc.)
1.2.7 BENEFITS OF COATING
Nowadays machining tools and dies used in the industry are coated in many different
colours. Modern tools have a greater variety of colours. The great increase in coated tools in
recent years reflects the high standard of modern day tools. The coatings are not for mere
8

decorative purpose but mainly to increase the durability of tools and dies. The surface of tools is
the first area to come into contact with the work piece and having strong and wear resistant
surface can prolong the life of tools and dies.
There are many types of technique to deposit hard coatings but the one offering the most hightech and more advantage is the PVD or Physical Vapour Deposition. The popular coating
materials used currently is compounds of Titanium and PVD can coat various forms of Titanium
compounds onto tools to meet the application requirement. Apart from enhancing strong and
durable surface PVD can also coat compounds that give attractive colours such as TiN ( Titanium
Nitride ) or TiZrN ( Titanium Zirconium Nitride ) having colour like gold for decorative purpose.
1.2.8 NEED OF PVD COATING ON TOOLS
The need for PVD Hard Coatings on tools and dies industry is increasing
continuously because of its outstanding engineering property and its cost saving advantage. PVD
coating offers the following benefit: 1. Increased wear resistance for tools and dies. 2. Increased
corrosion resistance for tools and dies. 3. Increased lubricity and improved release. 4. Reduced
galling. 5. Extended tools' life. 6. Increase in feed rate and cutting speed. 7. Less maintenance
and down time. 8. Cost saving in new tools and dies.

1.3 SUMMARY OF DRILLING PARAMETERS AND FORMULA

1.3.1 CUTTING SPEED
The speed of the work piece surface relative to the edge of the cutting tool during a cut,
measured in surface mm per minute.

1.3.2 SPINDLE SPEED

Speed always refers to the spindle and the work piece. When it is stated in revolutions per
minute (rpm) it tells their rotating speed. But the important feature for a particular turning
operation is the surface speed, or the speed at which the work piece material is moving past the
cutting tool. It is simply the product of the rotating speed times the circumference of the work
piece before the cut is started. It is expressed in meter per minute (m/min), and it refers only to
the work piece. Every different diameter on a work piece will have a different cutting speed,
9

even though the rotating speed remains the same. V = DN/1000 m/min Here, v is the cutting
speed in turning, D is the initial diameter of the work piece in mm, and N is the spindle speed in
RPM.
1.3.3 FEED RATE
The speed of the cutting tool's movement relative to the work piece as the tool makes a
cut. The feed rate is measured in inches per minute and is the product of the cutting feed (IPR)
and the spindle speed (RPM). Feed always refers to the cutting tool, and it is the rate at which the
tool advances along its cutting path. On most power-fed lathes, the feed rate is directly related to
the spindle speed and is expressed in mm (of tool advance) per revolution (of the spindle), or
mm/rev.
Fm = f.N mm/min
Here, F is the feed in mm per minute, f is the feed in mm/rev and N is the spindle speed in RPM.
1.3.4 MATERIAL REMOVAL RATE
The material removal rate (MRR) in turning operations is the volume of material/metal
that is removed per unit time in mm3/min. For each revolution of the work piece, a ring shaped
layer of material is removed.
MRR = (v. f .d 1000) in mm3 / min
1.4 CUTTING TOOL FOR LATHE
1.4.1 DRILL TOOL
A rotary end cutting tool having one or more cutting lips and having one or more helical
or straight flutes for the passage of chips and the admission of a cutting fluid.
1.4.2 HIGH SPEED STEELS (HSS)
HSS tools are so named because they were developed to cut at higher speeds.
Developed around 1900 HSS are the most highly alloyed tool steels. The tungsten (T series) was
developed first and typically contains 12 - 18% tungsten, plus about 4% chromium and 1 - 5%
vanadium. Most grades contain about 0.5% molybdenum and most grades contain 4 - 12%
cobalt. It was soon discovered that molybdenum (smaller proportions) could be substituted for
most of the tungsten resulting in a more economical formulation which had better abrasion
resistance than the T series and undergoes less distortion during heat treatment. Consequently
about 95% of all HSS tools are made from M series grades. These contain 5 - 10% molybdenum,

10

1.5 - 10% tungsten, 1 - 4% vanadium, 4% Chromium and many grades contain 5 - 10% cobalt.
HSS tools are tough and suitable for interrupted cutting and are used to manufacture tools of
complex shape such as drills, reamers, taps, dies and gear cutters. Tools may also be coated to
improve wear resistance. HSS accounts for the largest tonnage of tool materials currently used.
Typical cutting speeds: 10 - 60 m/min.
1.5 DRILL BIT NOMENCULTURE

AXIS
The imaginary straight line which forms the longitudinal center line of the drill.
BACK TAPER

A slight decrease in diameter from point to back in the body of the drill.
BODY
o The portion of the drill extending from the shank or neck to the outer Corners of

the cutting lips.

BODY DIAMETER CLEARANCE
o That portion of the land that has been cut away so it will not rub against the walls
of the hole.
CHISEL EDGE ANGLE
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The angle included between the chisel edge and the cutting lip, as viewed from the end of
the drill.

CLEARANCE DIAMETER
o The diameter over the cut away portion of the drill lands.
DRILL DIAMETER
o The diameter over the margins of the drill measured at the point.
FLUTES
o Helical or straight grooves cut or formed in the body of the drill to provide cutting
lips, to permit removal of chips, and to allow cutting fluid to reach the cutting

lips.
FLUTE LENGTH
o The length from the outer corners of the cutting lips to the extreme back end of
the flutes. It includes the sweep of the tool used to generate the flutes and,

therefore, does not indicate the usable length of the flutes.

HELIX ANGLE
o The angle made by the leading edge of the land with a plane containing the axis of
the drill.
LAND
o The peripheral portion of the body between adjacent flutes.
SLIP RELIEF ANGLE
o The axial relief angle at the outer corner of the lip. It is measured by projection
into a plane tangent to the periphery at the outer corner of the lip.

NECK
o The section of reduced diameter between the body and the shank of a drill.
OVERALL LENGTH
o The length from the extreme end of the shank to the outer corners of the cutting
lips. It does not include the conical shank end often used on straight shank drills,
nor does it include the conical cutting point used on both straight and taper shank
drills.

o
PERIPHERAL RAKE ANGLE
o The angle between the leading edge of the land and an axial plane at the drill
point.

POINT ANGLE
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o The angle included between the lips projected upon a plane parallel to the drill

axis and parallel to the cutting lips.

SHANK
o The part of the drill by which it is held and driven.

1.6 MATERIAL REMOVAL RATE

The material removal rate (MRR) in turning operations is the volume of material/metal
that is removed per unit time in mm3/min. For each revolution of the work piece, a ring shaped
layer of material is removed. MRR = (v. f .d 1000) mm3 / min
1.7 TOOL WEAR
Tool wear in machining is defined as the amount of volume loss of tool material on the
contact surface due to the interactions between the tool and work piece. Specifically, tool wear is
described by wear rate (volume loss per unit area per unit time) and is strongly determined by
temperature, stresses, and relative sliding velocity generated at the contact interface. Metal
cutting tools are subjected to extremely arduous conditions, high surface loads, and high surface
temperatures arise because the chip slides at high speed along the tool rake face while exerting
very high normal pressures (and friction force) on this face. The forces may be fluctuating due to
the presence of hard particles in the component microstructure, or more extremely, when
interrupted cutting is being carried out. Hence cutting tools need:

Strength at elevated temperatures

High toughness

High wear resistance

High hardness

It is common to assume that all the energy used in cutting is converted to heat (a reasonable
assumption) and that 80% of this is carried away in the chip (this will vary and depend upon
several factors - particularly the cutting speed). This leaves about 20% of the heat generated
going into the cutting tool. Even when cutting mild steel tool temperatures can exceed 550oC,
the maximum temperature high speed steel (HSS) can withstand without losing some hardness.
Cutting hard steels with cubic boron nitride tools will result in tool and chip temperatures in
excess of 1000oC.
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1.8 SURFACE ROUGHNESS

Surface roughness is an important measure of product quality since it greatly influences
the performance of mechanical parts as well as production cost. Surface roughness has an impact
on the mechanical properties like fatigue behavior, corrosion resistance, creep life, etc. It also
affects other functional attributes of parts like friction, wear, light reflection, heat transmission,
lubrication, electrical conductivity, etc. Before surface roughness, it is also necessary to discuss
about surface structure and properties, as they are closely related.
1.8.1 THE PRINCIPAL ELEMENTS OF SURFACE ROUGHNESS
The principal elements of surfaces are discussed below:
1. SURFACE:
The surface of an object is the boundary which separates that object from another
substance. Its shape and extent are usually defined by a drawing or descriptive specifications.
2. PROFILE:
It is the contour of any specified section through a surface.
3. ROUGHNESS:
It is defined as closely spaced, irregular deviations on a scale smaller than that of
waviness. Roughness may be superimposed on waviness. Roughness is expressed in terms of its
height, its width, and its distance on the surface along which it is measured.

4. WAVINESS:
It is a recurrent deviation from a flat surface, much like waves on the surface of water. It
is measured and described in terms of the space between adjacent crests of the waves (waviness
width) and height between the crests and Valleys of the waves (waviness height). Waviness can
be caused by,

Deflections of tools, dies, or the work piece,

Forces or temperature sufficient to cause warping,

Uneven lubrication,

14

Vibration or any periodic mechanical or thermal variations in the system during

manufacturing operations.

Fig.1.8.120 Surface characteristics

5. FLAWS:
Flaws, or defects, are random irregularities, such as scratches, cracks, holes, depressions,
seams, tears, or inclusions.
6. LAY:
Lay, or directionality, is the direction of the predominant surface pattern and is usually
visible to the naked eye.
1.8.2 FACTORS AFFECTING THE SURFACE FINISH
A) The machining variables which include a) Cutting speed b) Feed, and c)
Depth of cut. B) The tool geometry Some geometric factors which affect achieved surface finish
include: a) Nose radius b) Rake angle c) Side cutting edge angle, and d) Cutting edge. C) Work
piece and tool material combination and their mechanical properties D) Quality and type of the
machine tool used, E) Auxiliary tooling, and lubricant used, and F) Vibrations between the work
piece, machine tool and cutting tool.
1.8.3 MEASUREMENT OF SURFACE ROUGHNESS
1. Direct measurement methods 2. Comparison based techniques 3. Non contact methods
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4. On-process measurement

DIRECT MEASUREMENT METHODS

Figure (1.8.3) Schematic diagram of surface roughness measurement technique by stylus

Equipment Direct methods assess surface finish by means of stylus type devices. Measurements
are obtained using a stylus drawn along the surface to be measured. The stylus motion
perpendicular to the surface is registered. This registered profile is then used to calculate the
roughness parameters. This method requires interruption of the machine process, and the sharp
diamond stylus can make micro-scratches on surfaces.

CHAPTER-2
2. LITERATURE REVIEW

16

CHAPTER II
LITERATURE REVIEW
2.1 INTRODUCTION
The behaviour of a material is greatly dependent upon its surface, the environment
andits operating conditions. Surface engineering can be defined as the branch of science
that deals with methods for achieving desired surface requirements and behaviour in
service for engineering components [25]. The surface of any component may be selected
on the basis of texture and colour, but engineering components generally demand a lot
more than this. Engineering components must perform certain functions completely and
effectively under various conditions, possibly in aggressive environments. Modem
process environments, which contribute to wear, can be very complex, involving a
combination of chemical and physical degradation. Surface properties of the component
used in a particular workingenvironment have to be designed with that environment in
mind.
P.VENKATARAMAIAH [1] et al has Investigated on the controllable parameters
(cutting speeds, feed rates, type of drill tool, cutting fluids) of drilling operations with
influence the response of (torque, cutting force, surface roughness, material removal rate,
power) in En8. Drilling is undertaken HSS tool only, by using taughi method. It consist of
two phases artificial neural network (ANN) continued to that ANN is analyzed with S/N
ratio of Taughi approach. This work is useful in predicting the multi responses while
cutting different materials in different drilling parameters.
A.NAVANTH, T. KARTHIKEYA SHARMA [2] A study of taguchi method
based optimization of drilling parameter in dry drilling of al 2014 alloy at low speeds;
International Journal of Engineering Sciences & Emerging Technologies, August

17

2013.International Journal of Engineering and Advanced Technology (IJEAT) ISSN:

2249 8958, Volume-2, Issue-1, October 2012
M. MONTOYA [3] et al this paper aims to establish the wear mechanisms of
coated and uncoated tungsten carbide drills when drilling carbon fiber reinforced plastics
(CFRP)/aluminum alloy (Al) stacks. During the drilling experiments, thrust forces were
measured. For both coated and uncoated drills, abrasion was the dominant tool wear
mechanism, affecting the entire cutting edges higher wear was observed on uncoated
tools which caused a significant increase in thrust force during drilling both Al and CFRP
materials.
YOGENDRATYAGI [4] et al In this paper the drilling of mild steel with CNC
drilling machine by using a tool high speed steel by applying Taguchi methodology. A L9
array, taughi method and analysis of variance (ANOVA) are used to formulate the
procedure tried on the change of parameter. Design offers a systematic method for
optimization surface finish as well as high material removal rate (MRR).
TURGAYKIVAK [5] et al this paper focuses on the optimization of drilling
parameters using the Taguchi technique to obtain minimum surface roughness (Ra) and
thrust force (Ff). A number of drilling experiments were conducted using the L16
orthogonal array on a CNC vertical machining centre. The experiments were performed
on AISI 316 stainless steel blocks using uncoated and coated M35 HSS twist drills under
dry cutting conditions. It was found that the cutting tool was the most significant factor
on the surface roughness and that the feed rate was the most significant factor on the
thrust force
A.I. FERNNDEZ-ABIA [6] et al analyzed the market of turning tools is coped
majority by hard metal tools with CVD coating. However, availability of tools with
sharpcutting edges is essential in light turning of small parts. In this context, PVD process
18

is optimum for obtaining sharp edges.Therefore, a methodology is presented to evaluate

the performance of PVD advanced tools for turning of difficult to machinematerials. Four
coatings were tested: AlTiSiN (nACo), AlCrSiN (nACRo), AlTiN and TiAlCrN. The
analysis was developedcarrying out wear tests and analyzing different signals such as
cutting forces, EDX analysis of inserts, part roughness and insert image analysis. Results
indicate that the best coatings for turning of difficult to machine materials as austenitic
stainless steelsarenACo and AlTiN coatings, since they offer the best performance.
MUSTAFA KURT [7] et al the aim of the work reported here was to utilize
Taguchi methods to optimize surface finish and hole diameter accuracy in the dry drilling
of Al 2024 alloy. Although modern metal-cutting cutting speeds (30, 45, and 60 m/min),
feed rates (0.15, 0.20, and 0.25 mm/rev), depths of drilling (15 and 25 mm), and different
drilling tools (uncoated and TiN- and TiAlN- coated) with a 118 point angle.
Confirmation tests with the optimal levels of machining parameters are carried out.
A. RIVERO [8] et al As a result of the need to automate assembly in the aircraft
industry. The main difficulties in dry drilling are accelerated tool wear due to work piece.
Dry drilling tests were performed using uncoated drills and two different coatings
produced by means of an arc Evaporation PVD process. Experiments consisted of
machining with a 10-mm diameter three-edged drill to produce 25-mm deep joining
process in aircraft manufacturing .Tool wear evolution and burr size were analyzed, as
well as the impact of the process parameters on torque, power, feed, force and tool
temperature.
SONNY IRAWAN [9] et al has investigated onDrilling optimization aims to
optimize controllable variables during drilling operation such as weight on bit and bit
rotation speed for obtaining maximum drilling rate. From the research the constants that
represented several drilling variables had been determined. The rate of penetration for the
field had been predicted based on constants for every data vs. Depth. Finally, optimized
19

weight on bit had been calculated for several data points. In the end, drilling simulator
(Drill-Sim 500) was used to prove the results based on actual field data.
N.NELSION, R.T.RAKOWSKI, J. FRANKS,P. WOOLIAMS, P.WEAVER,
B.J.JONES [10] et al Potential applications of diamond-like carbon (DLC) coatings
range from precision tools and biomedical implants to micro mechanical devices and
engine components. Where uniform coatings are required on substrates with complex
geometries, plasma enhanced chemical vapour deposition (PECVD) is often a preferred
deposition method. As a non-line of sight process, the geometry of the substrate is often
considered negligible. For this reason analysis of PECVD coatings, such as amorphous
carbon, has mostly been concerned with reactor deposition variables, such as bias
voltage, pressure and gas ratios. Samples are therefore usually prepared and positioned to
minimise the influence of other variables. By depositing nominally similar DLC films on
silicon samples positioned horizontally and vertically on the reactor cathode plate it was
possible to examine the variations in the coating characteristics and mechanical
properties that occur due to the geometry of the substrate being coated.
Topographic measurements and analysis of bonding structures revealed significant
heterogeneity in the coatings. Electron microscopy showed variation in surfacestructure
aswell as thickness disparities of up to 50% in the vertical sample. Atomic force
microscopy showed roughness, Ra, varied from 0.37 nm to 15.4 nm between samples.
Raman spectroscopy highlighted variations in the sp2/sp3 bonding ratios whilst micro
wear tests demonstrated how these variations reduce the critical load performance. These
effects are explained in terms of the deposition mechanisms involved and are related
tovariation in deposition species and geometrical field enhancements within the
deposition chamber. Improved understanding of these local variations will aid in the
optimization of coatings for complex substrate geometries.
2.2 CONCULSION
20

From the above literature survey it is found that the minimum surface
wearD3alloy steels is not yet analyzed. Hence, in this investigation an attempt has been
made to study the process parameter Analysis onHigh carbon steels. This Experimental
study is very useful for carrying out further studies on metallurgical properties of the
coated materials.

3. TAGUCHI APPROACH
Basically, experimental design methods were developed original fisher. However
experimental design methods are too complex and not easy to use. Furthermore, a large number
of experiments have to be carried out when the number of the process parameters increases, to
solve this problem, the Taguchi method uses a special design of orthogonal arrays to study the
entire parameter space with a small number of experiments only. The experimental results are
then transformed into a signal to noise (S/N) ratio [1][2] to measure the quality
characteristics deviating from the desired values. Usually, there are three categories of quality
characteristics in the analysis of the S/N ratio, i.e., the lower better, the higher better, and
the nominal better. The S/N ratio for each level of process parameter is compared based on
the S/N analysis. Regardless of the category of the quality characteristic, a greater S/N ratio
corresponds to better quality characteristics. Therefore, the optimal level of the process
parameters is the level with the greatest S/N ratio Furthermore, a statistically significant with the
S/N and ANOVA[3] analyses, the optimal combination of the process parameters can be
predicted. Finally, a confirmation experiment is conducted to verify the optimal process
parameters obtained from the parameter design. There are 3 Signal-to-Noise ratios [5][6] of
common interest for optimization of Static Problems. The formulae for signal to noise ratio are
designed so that an experimenter can always select the largest factor level setting to optimize the
quality characteristic of an experiment. Therefore a method of calculating the Signal-To-Noise
ratio we had gone for quality characteristic. They are
1. Smaller-The-Better,
2. Larger-The-Better,

21

3. Nominal is Best.
1. SMALLER IS BETTER
The signal-to-noise (S/N) ratio is calculated for each factor level combination. The
formula for the smaller-is-better S/N ratio using base 10 log is: S/N = -10*log(S (Y2)/n) Where
Y = responses for the given factor level combination and n = number of responses in the factor
level combination.
2. LARGER IS BETTER
The signal-to-noise (S/N) ratio is calculated for each factor level combination. The
formula for the larger-is-better S/N ratio using base 10 log is: S/N = -10*log(S(1/Y2)/n) Where Y
= responses for the given factor level combination and n = number of responses in the factor
level combination.
3. NOMINAL IS BEST
The signal-to-noise (S/N) ratio is calculated for each factor level combination.
The formula for the nominal-is-best I S/N ratio using base 10 log is: S/N = -10*log (s2) Where s
= standard deviation of the

4 EXPERIMENTAL SETUP
In the present work, CNC lathe is used to drill holes on EN 31; the machining setup is
shown in figure

22

4.1 HIGH SPEED STEEL (HSS)

It is subset of tool steels, commonly used in tool bits and cutting tools. It is often used in
power-saw blades and drill bits. It is superior to the older high carbon tools used extensively
through the 1940s in that it can withstand higher temperatures without losing its temper
(hardness). This property allows HSS to cut faster than high carbon steel, hence the name high
speed steel at room. In this study, we were performed using 15.87- mm diameter HSS twist
uncoated drills, HSS TiAlN-coated drills, and HSS CrAlN-coated drills. It shows the
dimensional properties of the drilling tools. To guarantee the initial conditions of each test, a new
tool was used in each experiment.
4.2 COATED DRILL BITS
The most common methods of chromium nitride thin film creation are physical vapor
deposition (PVD, usually sputter deposition, cathodic arc deposition or electron beam heating)
and chemical vapor deposition (CVD). In both methods, chromium is sublimated and reacted
with nitrogen in a high-energy, vacuum environment. Chromium film may also be produced on
workpieces by reactive growth (for example,annealing) in a nitrogen atmosphere.

23

4.3 WORK MATERIAL DETAILS

Work material EN31
Work material thickness - 15mm

Figure (4.3) Work material

4.4WORK MATERIAL PREPARATION
The work piece material was EN 31, which is extensively used in the Automobile
industry and aerospace industry. The chemical and mechanical properties of EN 19 are shown
respectively.

4.5 CHEMICAL PROPERTIES

Chemical Composition
Fe
C
Si
Mn
P
S
Cr
Mo
Ni
Al

Chemical Composition
Fe 96.86%
C 0.38%
Si 0.21%
Mn 0.91%
P 0.01%
S 0.01%
Cr 1.04%
Mo 0.23%
Ni 0.23%
Al 4.21%
24

Steel grade and Chemical composition

Steel

grade:

BS EN

19

C(

):

0.36

0.44

Si(

):

0.10

0.35

Mn(

): 0.70

1.00

P(

): d

S(

): d

Cr(

):

Ni(

0.90

1.20

):

Mo(): 0.150.35
Other():

4P+Sn0.15

d - P0.035, S0.040
e- P0.035, S0.025 ~ 0.050
f- P0.025, S0.015 ~ 0.040

4.6 PHYSICAL PROPERTIES

Tensile

Yield

Strength

Stress

Rm N/mm

Re N/mm

700/850

Heat

Proof

Hardness

Size

HB

mm

a% on

Impact

Impact

5.665So

Izod J

KCV J

495

15

34

28

480

201/225

775/925

555

13

27

22

540

223/277

775/925

585

15

54

50

570

223/277

850/1000

680

13

54

50

665

248/302

Treatment

25

Stress
rp0.2

>100250

>150250

>63150

>29100

925/1075

755

12

47

42

740

269/331

>1363

1000/1150

850

12

47

42

835

293/352

>629

1075/1225

940

12

40

35

925

311/375

>619

Table (4.6) Physical properties

4.7 SURFACE FINISH MEASUREMENTS
Surftest SJ-201P: Surftest SJ-201P (Portable surface roughness tester) instrument is
widely used to measure the shape or form of components. A profile measurement device is
usually based on a tactile measurement principle. The surface is measured by moving a stylus
across the surface. As the stylus moves up and down along the surface, a transducer converts
these movements into a signal which is then transformed into a roughness number and usually a
visually displayed profile. Multiple profiles can often be combined to form a surface
representation. Surftest SJ-201P is shown in figure.

26

CHAPTER-5

5.1 DESIGN OF EXPERIMENT

Process parameters and their levels (3*2)
S.No

SPEED
FEED

1
200
0.03
2
300
0.08
3
400
0.1
AN ORTHOGONAL ARRAY L9(3*2)FORMATION
S. No
1
2
3
4
5
6
7
8
9

SPEED
200
200
S. No
200
300 1
300 2
300 3
400 4
400 5
400 6
7
8
9

FEED
0.03
0.08
SPEED
0.10
200 0.03
200 0.08
200 0.10
300 0.03
300 0.08
300 0.10
400
400
400

27

DRILLING TOOL
MATERIAL
HSS
HSS
FEED
DRILLING TOOL
HSS
MATERIAL
HSS
0.03
Chromium Nitride
HSS
0.08
Chromium Nitride
HSS
0.10
Chromium Nitride
HSS
0.03
Chromium Nitride
HSS
0.08
Chromium Nitride
HSS
0.10
Chromium Nitride
0.03
0.08
0.10

Chromium Nitride
Chromium Nitride
Chromium Nitride

5.2 Project methodology

The proposed work approach and methodology has been elaborately shown in the

Project Objective

STEP - 1

Data collection and Literature review

Studying and proposing a method&Machining process

Properties Analysis

STEP - 2

Optimization process

Conclusion

28

CHAPTER-6
CONCLUSION

The various parameters has to be selected for CNC turning machining. The work piece
will be planned with various parameters like DOC ,speed, feed.In order to achieve to high degree
surface finish aswellas minimum cycle timing. Along with that compare the process parameter
optimization of material in next phase.
.

Proposed work status

The following proposed work has been completed as phase 1

Objective (selection)

Collection of information

Method for conduct of machining on sample work piece.

Conducting the machining operation.

In phase - 2

Analyzing the experiment details.

Optimize the parameter

Conclusion.

Scope for future work.

29