Faculty Publications

Now showing 1 - 4 of 4

Experimental studies on turning of discontinuously reinforced aluminium composites under dry, oil water emulsion and steam lubricated conditions using TAGUCHI's technique
(Gazi University Eti Mahallesi, 2009) Shetty, R.; Pai B, R.B.; Rao, S.S.
This paper reports on the experimental investigations carried out under dry, oil water emulsion and steam lubricated conditions in turning of DRACs. The measured results were then collected and analyzed with the help of the commercial software package MINITAB15. The experiments were planned on orthogonal arrays, made with prefixed cutting parameters and different lubricated conditions. An analysis of variance (ANOVA) was carried out to check tho validity of the proposed parameters and also their percentage contributions. The results of the tests show that with proper selection of the range of cutting parameters, it is possible to obtain better performance under steam lubricated condition.
Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes
(Universidade Federal de Sao Carlos, 2014) Revankar, G.D.; Shetty, R.; Rao, S.S.; Gaitonde, V.N.
The present work deals with the investigation on machining of difficult-to-machine material titanium alloy (Ti-6Al-4V) using poly crystalline diamond (PCD) tool under different coolant strategies, namely dry, flooded and MQL. Taguchi technique has been employed and the optimization results indicated that MQL lubricating mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.25 mm depth of cut is necessary to minimize surface roughness and dry mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.75 mm depth of cut is necessary to maximize surface hardness. The results indicate the substantial benefit of the minimum quantity of lubrication (MQL) and justify PCD inserts to be the most functionally satisfactory commercially available cutting tool material for machining titanium alloys for better surface finish and hardness.
Development of novel cutting tool with a micro-hole pattern on PCD insert in machining of titanium alloy
(Elsevier Ltd, 2018) Rao, C.M.; Rao, S.S.; Herbert, M.A.
The development of a novel cutting tool that had a micro-hole pattern on their rake and flank face of cutting tool surface has found wider potential in the field of manufacturing. Micro-hole pattern features on a tool rake face help in controlling the tribological characteristics of the cutting tool. Micro-holes with the different number of holes orientation, diameter and depth were fabricated using the advanced application of the electrical discharge super drilling machine with the view to assist lubricant penetration and retention. A comparative study has been conducted between micro-hole patterned Polycrystalline Diamond (PCD) cutting insert and the commercially available PCD cutting insert. The effect of micro-hole pattern on the machining of Titanium alloy (Ti-6Al-4 V) is investigated with the application of the Minimum Quantity Lubrication (MQL) method in turning operation. Vibration signals were captured in feed force direction and measured using the tri-axial accelerometer. The cutting temperature, tool-wear, and chip-morphology were measured with an infrared thermometer and Scanning Electron Microscope (SEM). It was found that micro-hole textured inserts reduced the friction on the rake face resulting in the decrease of vibration up to 30–50%. The cutting temperature, tool wear and surface roughness were reduced to 30%, 50% and 40%, respectively. The conical and helical chips were produced in micro pool lubrication system. The friction coefficient can be minimized at the tool-chip interface by using liquid lubrication method. There is no unfavourable effect on the performance of cutting tools having holes on the cutting tool surface. All these parameters led to the improvement in the tool life. © 2018
Minimum Quantity Lubrication through the micro-hole textured PCD and PCBN inserts in the machining of the Ti–6Al–4V alloy
(Elsevier Ltd, 2021) Rao, C.M.; Sachin, B.; Rao, S.S.; Herbert, M.A.
A novel cutting tool development with the micro-hole textures on the flank and rake face of the cutting inserts helps in the reduction of tribological properties. The machining of Ti–6Al–4V alloy leads to some challenges during machining namely higher cutting temperature, and rapid tool wear. In this research, a comparison study has been performed with the new cutting tool inserts with surface modification such as Polycrystalline Cubic Boron Nitride (PCBN) and Polycrystalline Diamond (PCD) inserts for high-speed machining of Ti–6Al–4V alloy. The influence of the micro-hole textured insert on the machining of the Ti–6Al–4V alloy was investigated with the Minimum Quantity Lubrication (MQL) method. Compared to modified PCBN inserts, modified PCD inserts showed better results in all the performance characteristics. © 2020 Elsevier Ltd

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