Experimental investigation and performance analysis of inserts coated with nano materials in turning operation

Abstract

The industries are striving hard for manufacturing precision components Machining is one of the manufacturing processes for making any components The evolution of Computer Numerical Control CNC machines have made a massive leap in the area of machining Turning is a vital machining operation for making rotational parts so that the turning operation gets much attention in the industrial arena Many research and improvements are made in the area of turning operation One of the critical rotational component made in automobile industries is rotating shafts The quality of machined shafts by the turning operation had become vital The optimal machining parametric conditions and appropriate type of insert used to improve the quality of the machined shafts using CNC lathe Insert is the detachable part of the cutting tool Coating with suitable materials enhances the performance of the insert Machining with coated insert also improves the surface roughness of the machined shaft The nano materials are found to exhibit excellent mechanical properties In the present work it is decided to coat nano materials on the Insert and investigations are carried out in the machined workpiece The shaft material chosen for machining is AISI 4340 steel Hydraulic and gear applications use these type of shafts Lip seals are provided over the shafts in hydraulic rotary shaft applications to avoid the leakages through the shaft Thus the surface of the shafts should be even and smooth So that surface roughness of the shafts is significant The nano material coated inserts improve the surface roughness of the machined shafts chosen for coating on the inserts are Nickel TiAlN and SiO2 The TNMG inserts are coated with these nano materials using Physical Vapor Deposition PVD technique A minimum number of experiments conducted to minimizethe material wastage For machining three input parameters considered are speed feed and depth of cut These input parameters are varied to two levels Based on this using factorial design the number of experiments to be conducted is determined as eight experiments. newline