Conference Papers
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Item 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. © 2018 Elsevier Ltd.Item 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. © 2018 Author(s).Item 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. © 2020 Author(s).Item 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 μm 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. © 2020 Author(s).