Browsing by Author "V Badiger, P.V."

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Cutting Forces, Surface Roughness and Tool Wear Quality Assessment Using ANN and PSO Approach During Machining of MDN431 with TiN/AlN-Coated Cutting Tool
(Springer Verlag, 2019) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Prajwala, B.K.; Raveendra, K.
The aim of this study was to improve the life and performance of tungsten carbide turning tool inserts coated with TiN/AlN multilayer thin films using physical vapor deposition technique. Quality characteristics of the coating are evaluated using Calo and VDI 3198 tests. Thickness of the coating is found to be 3.651?m with adhesion quality of HF1. The performance of coated tool inserts is evaluated using cutting speed (59–118 m/min), feed rate (0.062–0.125 mm/rev) and depth of cut (0.2–0.4 mm) as process parameters in turning MDN431 steel. Experimental investigation has been carried out based on full factorial design, and regression analysis was used to analyze and build the mathematical models for cutting force and surface roughness. Multi-objective optimization of the process parameters has been done with the combination of desirability approach and MOPSO technique. Optimum machining condition for least cutting force and optimum surface roughness is found to be Vc=59m/min, f=0.063mm/rev and ap=0.2mm. Cutting force and surface roughness are reduced by 9% in TiN/AlN-coated tools compared with the uncoated tool. To improve the CoD and capability of predictive regression models, ANN modeling has been adopted. ANN trained model and mathematical regression models are used to predict the results and predict the responses, which follow the experimental data with minimum absolute error. The predicted results are validated using ANN and regression analysis found with minimum error, and developed models are adequate for further usage. Tool wear was reduced by 105% in TiN/AlN-coated tools compared with the uncoated tool. © 2019, King Fahd University of Petroleum & Minerals.
Development and Characterization of Ti/TiC/TiN Coatings by Cathodic Arc Evaporation Technique
(Springer India sanjiv.goswami@springer.co.in, 2017) V Badiger, P.V.; Desai, V.; Ramesh, M.R.
Metallic nitride and metallic carbide coatings in general have good resistance to wear. In particular they are coated on the metal surfaces subjected to wear/abrasion under chemically aggressive environments. In the present work, Titanium based multilayered hard coatings are developed on the highly-alloyed steel MDN121 by cathodic arc evaporation technique. The microstructure and mechanical properties of titanium based multilayer coatings are investigated to analyze the latent of these protective coatings. Coating morphology and elemental composition, surface topography, crystal phase and presence of Diamond like carbon are investigated using techniques of field emission scanning electron microscopy equipped with EDS, scanning tunneling microscopy, glancing angle XRD, and Raman spectroscopy. The results indicate that the coatings developed are defect free, dense, homogeneous, and a coating thickness in the range of 1–2 µm is achieved. Hardness and elastic modulus of the coatings have been measured using nano indentation technique and are found to be 5.60 and 297.60 GPa respectively. The adhesions of the coatings have been measured using the nano scratch test and critical load is found to be at 47.70 mN. © 2017, The Indian Institute of Metals - IIM.
Effect of cutting parameters on tool wear, cutting force and surface roughness in machining of MDN431 alloy using Al and Fe coated tools
(Institute of Physics Publishing helen.craven@iop.org, 2019) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Prajwala, B.K.; Raveendra, K.
Thin solid films are used in cutting tools in order to improve its performance, reduce tool wear and improve tool life. Cathodic arc evaporation is the state of art PVD technique widely accepted in industries for the development of thin solid films. The turning cutting tool inserts are coated with AlCN/AlC and FeCrN monolayer thin solid films using cathodic arc evaporation technique. Quality characteristics of thin films are estimated using Calo and VDI3198 tests. Thickness of the coatings are found to be 1.430 and 1.475 ?m for AlCN/AlC and FeCrN coatings respectively and adhesion quality of HF1 is attained. Performance of the thin solid films are evaluated in machining MDN431 steel with range of cutting speed (59-118 m min-1), feed rate (0.062-0.125 mm/rev) and depth of cut (0.2-0.4 mm). Experiments are performed based on full factorial design and regression analysis. Optimization of the process parameters is carried out using combined techniques of desirability and Particle swarm optimisation (PSO). The objective of the study is to establish correlation between machining parameters with cutting force, tool wear and surface roughness. Optimal process parameter for least cutting force and surface roughness are obtained for coatings. ANN has been adopted to improve the coefficient of determination (CoD) and capability of predictive regression models. ANN trained model and mathematical regression models are adequate to predicted the responses, which follows the experimental data with minimum absolute error. The AlCN/AlC coatings exhibited lower cutting forces and surface roughness than FeCrN coated tools. Tool wear was reduced by 3.62 times in AlCN/AlC and 1.63 times in FeCrN coated tools compared to uncoated tool which is due to increased hardness and elastic modulus of the coating. © 2018 IOP Publishing Ltd.
Experimental study of machinability factors in machining of AL6061-B4C composites: DoE approach
(ModTech Publishing House office@hotelfloramamaia.ro, 2018) V Badiger, P.V.; Kumar, S.; Auradi, V.; Hiremath, V.
In the present work the surface generation is studied during dry turning of Al6061-B4C metal-matrix composites, and was investigated based on analytical approaches which include DoE analysis. Al6061 is reinforced with B4C MMC’s were produced using stir casting method. The prepared MMC’s were characterized under SEM, EDAX and XRD tests. The tests were confirmed the B4C were fairly distributed in Al6061 alloy. Poly Crystalline Diamond (PCD) brazed tool is used for machining of MMC’s. Analytical approach was performed to explore the inter-relation between the process parameters, and its effect on surface roughness, cutting forces, tool tip temperature and built-up edge. The effects of machining parameters like speed, feed, depth of cut is varied to level-3 with a confidence level of 95%, and responses of machinability cutting forces were measured using lathe tool dynamometer, surface roughness using surface tester and temperature measured using heat gun. After the machining the tool tip is adhered with built up edge which is measured in INSIZE Microscope Analyzer. © 2018 International Journal of Modern Manufacturing Technologies.
Influence of Ti coated tools on process parameters in turning process of MDN431
(American Institute of Physics Inc. subs@aip.org, 2020) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Mahesh, M.; Santhosh, C.M.; Prajwala, B.K.; Raveendra, L.
Tungsten carbide tool places in are coated by customized composition of Ti/TiCN/TiN/TiCN/TiN for multilayer and monolayer TiC-C using PVD assisted CAE technique. Quality physiognomies of coatings are evaluated using VDI3198 and Calo tests. Thickness of the coatings for Ti-multilayer and monolayer are found to be 1.837 and 1.198 Î¼m respectively and adhesion quality of HF1 attained. Highly alloyed steel MDN431 is used as machining material to evaluate the performance of coatings. The coated tool insert performance has been evaluated at the machining parameters cutting speed in the range of 59-118 m/min, feed rate is 0.062-0.125 mm/rev and depth of cut is ap 0.2-0.4 mm during machining of MDN431 steel. Experiments are conducted based on L27 full factorial design. Cutting forces and surface roughness are analysed using regression analysis. Desirability approach as well as PSO technique is used to optimize the process parameters. Least cutting force and surface roughness are obtained at the condition of Vc-118 m/min, f-0.063 mm/rev, ap-0.2 mm and Vc-59 m/min, f-0.63 mm/rev, ap - 0.2 mm for Ti-multilayer and TiC-C coatings respectively. To augment the capability of predictive regression models and coefficients of determination (COD), ANN modelling has been adopted. Cutting forces and surface roughness are predicted using ANN and mathematical regression models, predicted data follows the experimental data with minimum absolute error. Tool wear was reduced by 65.7% in Ti-multilayer and TiC-C coated tools compared to uncoated tool. Â© 2020 Author(s).
Machinability studies on EN47 spring steel by optimization technique during dry and wet condition
(ModTech Publishing House office@hotelfloramamaia.ro, 2019) Mallesha, V.; Hanumanthappa, S.N.; V Badiger, P.V.; Mahesh, V.
EN47 Spring steel is a hard material having a hardness of 45-48HRC. EN47 material possesses low thermal conductivity and suitable for oil hardening and tempering. Hardened spring steel offers excellent toughness and shock resistance, suitable alloy for automobile applications. In this experimental study, to optimize the process parameters such as cutting speed (Vc), feed rate (f) and depth of cut (ap). In order to minimize the surface roughness (Ra), tool tip temperature (T) and tangential cutting force (Fz) during turning of spring steel by coated tungsten carbide cutting tool insert under dry and wet condition. Experiments are conducted based on the design of experiment using full factorial design (33: three factors and three levels) L27 orthogonal array. From the experimental work, result reveals that surface roughness (Ra) influenced by (Vc and f). Tangential cutting force (Fz) influenced by (f and ap). Tool tip temperature influenced by (Vc and ap). The comparison have been done between dry and wet condition and the results reveal that under wet condition surface roughness (Ra) and tool tip temperature (T) is reduced by 22.59% and 21.29% respectively. Less difference was observed in cutting force (Fz) during dry and wet machining. © International Journal of Modern Manufacturing Technologies.
Optimisation of machining parameters for end milling of maraging steel MDN 250 using TiAlSiN and TiSiN coated WC-Co inserts
(American Institute of Physics Inc. subs@aip.org, 2020) Varghese, V.; Jagmalpuria, A.; V Badiger, P.V.; Ramesh, M.R.
Thin film coatings TiSiN, TiAlSiN were deposited on WC-Co milling inserts using RF magnetron sputtering. The machinability studies of maraging steel is carried out using thin film coatings of TiSiN TiAlSiN. The maching parameters of cutting speed, feed rate and depth of cut will be varied to analyse machining responses such as surface roughness and cutting force. The performance of each coating will be evaluated and compared along with tool wear and tool life. A Taguchi based grey relational analysis will be used to optimize the machining parameters and analysis of variance (ANOVA) is used to find the most significant factor. Â© 2020 Author(s).
Optimization of machining parameters in turning process of mdn431 using ti-multilayer coated tool
(ModTech Publishing House office@hotelfloramamaia.ro, 2018) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Raveendra, K.
WC-Co Cutting tool inserts are coated with tailored composition of Ti/TiCN/TiN/TiCN/TiN using cathodic arc evaporation technique. MDN431 is one of highly alloyed steel with tailored mechanical properties. MDN431 material is machined with Ti/TiCN/TiN/TiCN/ TiN coated and uncoated Co-based WC tool inserts. Machining parameters; cutting speed (398-625rpm), feed rate (0.093-0.175mm/rev) and depth of cut (0.1-0.5mm) and experiments are conducted according to response surface methodology center composite rotatable design. Surface roughness and cutting forces are measured for each iteration and the same analyzed for significance. Result reveals that for optimum surface roughness is obtained at the condition of high speed, low feed and low depth of cut. For optimum cutting force high speed, low feed and low depth of cut is preferred. Coated tools performed better in the study with increased tool life, reduced cutting force & surface roughness. At the optimum machined conditions machined surface are analyzed using optical profilometer. Central composite rotatable design developed mathematical models for cutting force and surface roughness for the prediction of results. The predicted results are minimum error and developed model is adequate for further usage. © International Journal of Modern Manufacturing Technologies.
Performance of DLC coated tool during machining of MDN431 alloyed steel
(Elsevier Ltd, 2018) V Badiger, P.V.; Desai, V.; Ramesh, M.R.
Highly alloyed steel are widely used in manufacturing of turbine materials because of its high resistance to corrosion and oxidation. MDN 431 is one of such material manufactured by Midhani. It's having high hardness and strength which makes it hard-to-machine steel. DLC coating provide solution to this problem. DLC coating are developed using state of art PVD technique on the HSS tool. Turning process carried out on MDN431 steel using coated and uncoated HSS tool insert in both wet and dry condition. During the present investigation, speed, feed, and depth of cut varied according to full factorial design with level 3, consequently cutting forces, surface roughness (Ra) and tool wear were measured. The obtained results are optimized using factorial method for cutting forces and surface roughness. Using FFD method second order regression analysis carried out for each input variable and same compared with experimental values and found the developed model is with minimal error which supported by proof trials. Speed and depth of cut are inversely dependent on the cutting force and surface roughness whereas feed is opposite to it. Effect of DLC coating during machining of MDN431 is studied using optical profilometry in comparison with uncoated tool. Â© 2018 Elsevier Ltd.
Performance of Ti-multilayer coated tool during machining of MDN431 alloyed steel
(American Institute of Physics Inc. subs@aip.org, 2018) V Badiger, P.V.; Desai, V.; Ramesh, M.R.
Turbine forgings and other components are required to be high resistance to corrosion and oxidation because which they are highly alloyed with Ni and Cr. Midhani manufactures one of such material MDN431. It's a hard-to-machine steel with high hardness and strength. PVD coated insert provide an answer to problem with its state of art technique on the WC tool. Machinability studies is carried out on MDN431 steel using uncoated and Ti-multilayer coated WC tool insert using Taguchi optimisation technique. During the present investigation, speed (398-625rpm), feed (0.093-0.175mm/rev), and depth of cut (0.2-0.4mm) varied according to Taguchi L9 orthogonal array, subsequently cutting forces and surface roughness (Ra) were measured. Optimizations of the obtained results are done using Taguchi technique for cutting forces and surface roughness. Using Taguchi technique linear fit model regression analysis carried out for the combination of each input variable. Experimented results are compared and found the developed model is adequate which supported by proof trials. Speed, feed and depth of cut are linearly dependent on the cutting force and surface roughness for uncoated insert whereas Speed and depth of cut feed is inversely dependent in coated insert for both cutting force and surface roughness. Machined surface for coated and uncoated inserts during machining of MDN431 is studied using optical profilometer. Â© 2018 Author(s).
Tribological behaviour of monolayer and multilayer Ti-based thin solid films deposited on alloy steel
(Institute of Physics Publishing helen.craven@iop.org, 2019) V Badiger, P.V.; Desai, V.; Ramesh, M.R.; Joladarashi, S.; Gourkar, H.
The fretting wear and adhesive wear resistance of Ti-based thin solid films deposited on MDN121 steel substrate are evaluated. Plasma-assisted cathodic arc evaporation technique is used to develop the TiC-C monolayer coating and Ti/TiN/TiCN/TiN/TiCN multilayer coatings used in the study. FESEM-EDS, nanoindentation, Raman spectroscopy, optical profiler, and confocal microscope are used to characterise the coatings and wear tracks. Diamond-like carbon is observed in the microstructure of both the coatings. During the fretting analysis, the coefficient of friction (COF) is reduced by 68.49% in the case of the TiC-C monolayer coating and 42.46% in the Ti multilayer coatings as compared to the substrate. The volumetric wear loss of the TiC-C monolayer coating is lower than the multilayer coating. The wear surface morphology reveals the abrasive form of the fretting wear mechanism in both the monolayer and multilayer coatings whereas the galling failure in the substrate. During adhesive wear, the COF is reduced by 71.73% in the monolayer coating and 59.33% in the multilayer coatings compared to the substrate. The monolayer coating exhibits low friction and low wear rate as compared to the multilayer coating. © 2018 IOP Publishing Ltd.