Conference Papers

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Has files: NoSubject: search.filters.subject.High Chrome White Cast Iron (HCWCI)

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    Development of thermal model to analyze thermal flux distribution in thermally enhanced machining of high chrome white cast iron
    (American Institute of Physics Inc. subs@aip.org, 2018) Ravi, A.M.; Murigendrappa, S.M.
    In recent times, thermally enhanced machining (TEM) slowly gearing up to cut hard metals like high chrome white cast iron (HCWCI) which were impossible in conventional procedures. Also setting up of suitable cutting parameters and positioning of the heat source against the work appears to be critical in order to enhance the machinability characteristics of the work material. In this research work, the Oxy - LPG flame was used as the heat source and HCWCI as the workpiece. ANSYS-CFD-Flow software was used to develop the transient thermal model to analyze the thermal flux distribution on the work surface during TEM of HCWCI using Cubic boron nitride (CBN) tools. Non-contact type Infrared thermo sensor was used to measure the surface temperature continuously at different positions, and is validated with the thermal model results. The result confirms thermal model is a better predictive tool for thermal flux distribution analysis in TEM process. © 2018 Author(s).
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    Experimental study on internal cooling system in hard turning of HCWCI using CBN tools
    (American Institute of Physics Inc. subs@aip.org, 2018) Ravi, A.M.; Murigendrappa, S.M.
    In recent times, hard turning became most emerging technique in manufacturing processes, especially to cut high hard materials like high chrome white cast iron (HCWCI). Use of Cubic boron nitride (CBN), pCBN and Carbide tools are most appropriate to shear the metals but are uneconomical. Since hard turning carried out in dry condition, lowering the tool wear by minimizing tool temperature is the only solution. Study reveals, no effective cooling systems are available so for in order to enhance the tool life of the cutting tools and to improve machinability characteristics. The detrimental effect of cutting parameters on cutting temperature is generally controlled by proper selections. The objective of this paper is to develop a new cooling system to control tool tip temperature, thereby minimizing the cutting forces and the tool wear rates. The materials chosen for this work was HCWCI and cutting tools are CBN inserts. Intricate cavities were made on the periphery of the tool holder for easy flow of cold water. Taguchi techniques were adopted to carry out the experimentations. The experimental results confirm considerable reduction in the cutting forces and tool wear rates. © 2018 Author(s).
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    Wear studies in hard turning of high-chrome white cast iron using ANOVA and RSM techniques
    (American Institute of Physics Inc. subs@aip.org, 2020) Ravi, A.M.; Murigendrappa, S.M.
    In these days, tool wear is a major concern in hard turning process. Though the hybrid machining and thermally enhanced machining methods relieved the burden of the Industry to some extent, tool wear studies are more vital in order to improve the productivity. This research work mainly focuses on such studies wherein the influence of cutting parameters and tool temperature on tool wear are investigated both experimental and analytical procedures. The work material selected for the process was high-chrome white cast iron (HCWCI) and cutting tool as multi-layer hard coated carbide inserts. The experimental trials were carried out in accordance with the Taguchi's techniques. Second order regression was established to build the linear relationship among the process parameters and its responses. The research study reveals that flank and crater wear are the dominant wear patterns appeared in the process. The influencing parameters and their interactive effects on tool wear are also presented in graphical form which may useful while choosing the process parameters for better tool life. © 2020 Author(s).
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    Comparative Study of Carbide Tools in Turning of High-Chrome White Cast Iron using Hard Turning Methods
    (IOP Publishing Ltd, 2021) Ravi, A.M.; Murigendrappa, M.
    Thermally enhanced machining (TEM) is a new practice in hard turning of hard materials like White cast iron, Inconel 718 steels etc. Addition of preheating before shear zone improves the elasticity of the material. Before this, Industries invested more capital on toolings and robust machineries/equipments, also it demamed high cost diamond, Cubic boran nitride (CBN) and polyCBN (pCBN) tools. This research paper mainly focusses on the comparative study of machinability characteristics like machining forces and surface roughness of a high hard High chrome white cast iron (HCWCI) when turning with and without the addition preheat using multilayer hard coated carbide (TiC/TiCN/Al2O3). Taguchi technique were used to carryout the experimentational work. The experimental and theoretical investigations are done in different phases in order to derive some of the useful process responses like machining forces, surface roughness etc, and to prove Oxy-LPG aided TEM most appropriate methodology to cut HCWCI. Furthermore derived the suitable conditions at which the coated carbide tools perform better. Hence comparative studies of each process responses are required to arrive to the reasonable conclusions. © Published under licence by IOP Publishing Ltd.
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    Development of internal cooling system in hard turning of annealed HCWCI using carbide tools
    (Association of American Publishers, 2025) Ravi, A.M.; Murigendrappa, S.M.
    In today’s manufacturing techniques, hard turning became the most rising technique to cut high hard materials like high chrome white cast iron (HCWCI). The use of Cubic boron nitride (CBN), Polycrystalline Cubic boron nitride (pCBN) and Carbide tools are most appropriate to shear the metals but are uneconomical. These materials are cut in dry condition, which results in lower life and can be enhanced by minimizing the tool temperature. The research study exposes effective tool cooling systems that can improve tool life and machinability characteristics, also proper selection of cutting parameters to control the cutting temperature. The main aim of this paper is to develop an ideal cooling system to control tool temperature, thereby minimizing the tool wear rates and cutting forces. In this research work, experiments were conducted on annealed high chrome white cast iron using carbide inserts. Intricate cavities were made on the toolholder body for easy circulation of cold water. Statistical tools were used to carry out the experimentations and its analysis. The result confirms, intercooling system minimizes the cutting forces and tool wear at considerable rates compared to non-intercooling system. © 2025 by authors.