Review of Effect of Tool Nose Radius on Cutting Force and Surface Roughness
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This document reviews the effect of tool nose radius on cutting force and surface roughness in machining processes. It summarizes several previous studies that have examined how tool nose radius influences factors like surface finish, tool wear, cutting forces, heat generation, and residual stresses. The studies found that larger tool nose radii generally produce finer surface finishes but greater tool wear. Increasing nose radius also tends to increase cutting forces but decrease surface roughness. The document aims to further evaluate how nose radius affects cutting force, tool wear, and residual stresses in metal turning.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 701
V = Cutting speed in M/Min
n = Index depends upon tool and work
C = Constant
1.4.1 The Ways of Representing Tool Life
Some of the ways of expressing tool life:
1. Time unit
2. Volume of metal removed expressing tool life
3. Number of work piece machined per grind
1.4.2 The Factors Affecting Tool Life
1. Feed and depth of cut
2. Cutting speed
3. Tool material
4. Tool geometry
5. Work material
6. Cutting fluid
7. Rigidity of work, tool and machine
2. AIM AND OBJECTIVE OF WORK
Nose radius is a parameter used in various cutting
and machining process. Describing the angle of cutting
face. In tool geometry selection of tool nose radius is
not an independent variable in process because the
effect of tool nose radius depends on cutting tool
geometry and cutting process.
The aim and objective of this study are as follows
1. To study the influence of nose radius on metal
turning process.
2. To evaluate cutting force.
3. To find tool wear and decrease it.
4. To decreases residual stresses.
3. LITERATURE REVIEW
Y. Kevin Chou et al. 2004 [1] The tool nose radius
effects is examined by finish turning of hardened AISI
52100 sheets of steel. The different conditions like
Surface finish, tool wear, cutting forces are observed
whilephasetransformation,werewhitelayerstructure
is obtained. Results show that onlylargetoolnoseradii
give finer surface finish, but as compare to small nose
radius tool wear in large tool nose radius is more. with
tool nose radius Specific cutting energy slightly
increases. For new tools, white layers only occur at
aggressive feeds (=0.3 mm/rev) and small nose radius
results in deeper white layers. For worn tools, white
layers appear even at mild feeds (0.05 mm/rev), but in
contrast, large nose radius leaves deeper white layers.
Maheshwari Patil et al. 2014 [2] From this paper we
focus on the effect of H.S.S. single point cutting tool
nose radius on cutting edge strength and tool wear in
machining of EN9.it is important to increase tool life
because of cost of the cutting tool is high, so we have to
pay attention to it. To understanding mechanics of
turning tool geometry the effect of cutting tool
geometry has long been an issue in understanding
mechanics of turning tool geometry has a significant
influence onchip formation, heatgeneration,toolwear
and surface finishsurfaceintegrityduringturning.This
paper presents a survey on variation in tool geometry
that is tool nose radius, rake angle, variable edge
geometry and theireffectontoolwearandcuttingedge
integrity in the turning operation of components from
EN9 (C45) plain carbon steel. The Heat generated
during turning is affected by edge preparation due to
change in work material flow around the cutting edge
Tool wear had the greatest influence on magnitude of
residual stress the level of microstructural alteration
The result which is obtained from various testisuseful
in selecting appropriate rake angle and nose radiusfor
various conditions of speed, feed and depth of cut](https://image.slidesharecdn.com/irjet-v4i2132-171115095311/85/Review-of-Effect-of-Tool-Nose-Radius-on-Cutting-Force-and-Surface-Roughness-3-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 702
which leads to economical machining and improved
productivity.
J. Naga Malleswara Rao et al. 2010 [3] In this
experiment new type of dynamometer to measure
radial of a component of cutting force using strain
gauges. Dynamometer is used to measure the cutting
force in any metal cutting process. The working
principle of dynamometer is calibrated and readings
are obtained andspecimenistestedforperformance.It
is mostly used in roller burnishing process on
aluminum work piece under various conditions in
rollers burnishing process, a hard roller is pressed
against a rotating cylindrical workpieceandparallelto
the axis of the work piece on lathe. From different
lubricant applications in roller burnishing operation
Optimum values of burnishing force and the
corresponding surface roughness value (Ra) are
obtained. This dynamometer can be manufacturedata
low cost. This dynamometer can be used for tests on
lathe in metal cutting laboratories and engineering
colleges. Variation in depth of cut can’t influence of the
corner radius on the cutting forces.
B.Tulasiramarao1 et al. 2014 [4] The cutting force can
be measure by Research focusing on a lathe tool
dynamometer,thrust/Axialforceandalsofeedforceby
usingstraingaugeaccelerometerhasbeenStudied.The
dynamometer applied in this experiment is a 500kg
force 3-component system. To a data acquisition
system the dynamometer is to be connected. Whenthe
tool comes in contact with the work piece the different
forces are produces and they can capture and
transformed into numerical form system. In these
experiment different forces for four various materials
and the materials used in this project are aluminum,
brass; mild steel & nylon have been noted down. The
variation in depth of cut is studied by the forces on
these different materials with it. Forces vary due to
variation in depth of cut are shown by Graphical
representation.
Moaz H. Ali et al. 2014 [5] In this work, they are
focusing to use a wide range of tools and techniques to
ensure that the designs they are created it saves.
Sometimes accidents happen when they are work in
the laboratories or factories. To know success
industries need to know whether a product failed or
how much percentage need.
4. CONCLUSIONS
After reviewing much paper related to nose radius,
rack angle, feed rate etc. They can be affected the
cutting force and surface roughness from above study
it is clear that tool nose radius is a most important
parameter in single cutting point tool. The result
obtaining from the various literature surveys the
following conclusion is state-
1. As a nose radius may be increased then effect
on cutting force also get increases.
2. Surface roughness gets decreases with respect
to increasing in nose radius.
3. Increase in feed rate can also increase the
surface roughness.
ACKNOWLEDGEMENT
It is a pleasure for us to present this paper where
guidance plays an invaluable key and provides a
concrete platform for completion of the paper.](https://image.slidesharecdn.com/irjet-v4i2132-171115095311/85/Review-of-Effect-of-Tool-Nose-Radius-on-Cutting-Force-and-Surface-Roughness-4-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 703
We would also like to thank our internal guide
Asst. Prof. S. B. Deokar Department of Mechanical
Engineering, for his valuable encouragement and
constant scrutiny without which we wouldn’t have
looked deeper into our work and realized both our
shortcomings and our feats. This work would not have
been possible without him.
REFERENCES
[1] Y. Kevin Chou, Hui Song, Tool nose radius effects
on finish hard turning, Journal of Materials
Processing Technology 148, 2004, pp. 259–268.
[2] Maheshwari Patil, Dr. R. J.Patil, StudyEffectofHSS
Single Point Cutting Tool Nose Radius on Cutting
Edge Strength andToolWearinMachiningofEN9,
International Journal of Science and Research
(IJSR), 12, December 2014, Volume 3, pp. 2563-
2567.
[3] J. Naga Malleswara Rao, A. Chenna Kesava Reddy
and P.V. Rama Ra, Design and fabrication of new
type of dynamometer to measure radial
component of cutting force and experimental
investigation of optimum burnishing force in
roller burnishingprocess,IndianJournalofScience
and Technology, July 2010, Vol. 3 No. 7.
[4] B. Tulasiramarao, Dr. K.Srinivas,Dr.PRamReddy,
A.Raveendra and Dr. B. V. R. Ravi Kumar, Finding
Cutting Forces While Turning Aperation on Lathe
Machine at Different Depth of Cut of Different
Metals, International Journal of Innovative
Research in Science, Engineering andTechnology,
oct 2014, Vol. 3 pp. 16867-16872.
[5] Moaz H. Ali, M. N. M. Ansari, The Effect of Nose
Radius on Cutting Force and Temperature during
Machining Titanium Alloy (Ti-6Al-4V),
International Journal of Mechanical, Aerospace,
Industrial, Mechatronic and Manufacturing
Engineering, 2014, Vol:8, No:12 pp. 2124- 2127.](https://image.slidesharecdn.com/irjet-v4i2132-171115095311/85/Review-of-Effect-of-Tool-Nose-Radius-on-Cutting-Force-and-Surface-Roughness-5-320.jpg)
Review of Effect of Tool Nose Radius on Cutting Force and Surface Roughness
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 699 Review of Effect of Tool Nose Radius on Cutting Force and Surface Roughness Vaykhinde Akash S.1, Bhor Ulhas B.2, Sachhe Vaibhav V.3, Valte Samrat P.4, Asst. Prof. S. B. Deokar5 1BE Student, Department of Mechanical Engineering, SND COE & RC, Maharashtra, India 2BE Student, Department of Mechanical Engineering, SND COE & RC, Maharashtra, India 3BE Student, Department of Mechanical Engineering, SND COE & RC, Maharashtra, India 4BE Student, Department of Mechanical Engineering, SND COE & RC, Maharashtra, India 5 Asst. Professor, Department of Mechanical Engineering, SND COE & RC, Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract – Machining is most important and common process in manufacturing. Various different types of cutting tool are used for cutting the different metals. There is a different type of cutting tool like single point cutting tool and multi-point cutting tool. Rake angle, flank angle, nose radius and other tool geometry are the different parametersofsingle point cutting point tool. The main effect on metal cutting is by rake angle, clearance angle, and nose radius. The nose radius having more effect on the surface roughnessandcuttingforce. Feed rate also having the identical effect on the cutting force and surface roughness. Nose radius and cutting forceand feed force are directly proportional and nose radius increases surface roughness is indirectly proportional. In this paper, the various forces such as cutting force, feed force and the axial force have been found out with the variation in depth of cut for EN8 materials. Graphs are drawn on how these forces vary with the variation in the depthofcut. The cutting force during turning is measured by using two- dimensional tool dynamometer and surface roughness is measured by using profilometer. Key Words: Tool nose radius, tool dynamometer, cutting force, surface roughness. 1. INTRODUCTION In metal turning process, for achieving certain shape, layer, size and surface quality of work piece for cutting tool required. There are many type of cutting tool developed to satisfy the requirement production for smooth running. The dimensions and shapes of work piece either determine by graphically and analytically during design. For greater productivitytherearemany researches are carried for decrease production cost and increase quality. There are many cutting parameter as follows: i. Rake angle ii. Depth of cut iii. Feed rate iv. Cutting speed In machining process there are twp type of method are implemented. To determine the effects of the parameters although most of the cutting processes are oblique, orthogonal cutting techniques are used in experiments of two dimensional mechanical workpiece. Important factors like cutting speed, tool rigidity and depth of cut, feed rate and tool geometry are determining the behavior of machinability of mechanical workpiece. 1.1 Types of Cutting Tools 1. Single point cutting tool 2. Multi-point cutting tool 1. Single point cutting tool- Single point cutting tool has only one cutting edge. This tool is used for various operation likes
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 700 boring, turning, shaping, facing this tool is used on a various machine like lathe machine, boring machine, shaper planer, etc. Fig-1: Features of a single point tool 1.2 The various cutting parameters i. Nose radius ii. Rack angle iii. Depth of cut iv. Feed rate v. Cutting speed vi. Cutting force vii. Surface roughness i. Nose radius: Nose radius is joint of side and end cutting edges by means of small radius by this increased life of the tool and better. ii. Rack angle: It is the angle between normal to the finished surface in a plane perpendicular to the cutting edge. iii. Depth of cut: It is the volume of work piece material that can be removed by the machining process. iv. Feed rate: It is the velocity of tool to the machining process. v. Cutting speed: It is relative speed between the surface of work piece and cutting tool. Fig -2: Various parts of single point cutting tool 1.3 Types of metal cutting process Classification of metal cutting process a) Orthogonal cutting process (Two-dimensional cutting) b) Oblique cutting process (Three-dimensional cutting) a) Orthogonal Cutting: The cutting edge of the tool is perpendicular to the work piece axis. b) Oblique Cutting: The cutting edge is inclined at an acute angle with normal to the cutting velocity vector is called oblique cutting process 1.4 Tool Life The timeelapsedbetweentwoconsecutivetool reshaping is called tool life. During this period thetool works effectively and efficiently. Taylor’s Tool Life Equation Vtn = C Where t = Tool life in minute
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 701 V = Cutting speed in M/Min n = Index depends upon tool and work C = Constant 1.4.1 The Ways of Representing Tool Life Some of the ways of expressing tool life: 1. Time unit 2. Volume of metal removed expressing tool life 3. Number of work piece machined per grind 1.4.2 The Factors Affecting Tool Life 1. Feed and depth of cut 2. Cutting speed 3. Tool material 4. Tool geometry 5. Work material 6. Cutting fluid 7. Rigidity of work, tool and machine 2. AIM AND OBJECTIVE OF WORK Nose radius is a parameter used in various cutting and machining process. Describing the angle of cutting face. In tool geometry selection of tool nose radius is not an independent variable in process because the effect of tool nose radius depends on cutting tool geometry and cutting process. The aim and objective of this study are as follows 1. To study the influence of nose radius on metal turning process. 2. To evaluate cutting force. 3. To find tool wear and decrease it. 4. To decreases residual stresses. 3. LITERATURE REVIEW Y. Kevin Chou et al. 2004 [1] The tool nose radius effects is examined by finish turning of hardened AISI 52100 sheets of steel. The different conditions like Surface finish, tool wear, cutting forces are observed whilephasetransformation,werewhitelayerstructure is obtained. Results show that onlylargetoolnoseradii give finer surface finish, but as compare to small nose radius tool wear in large tool nose radius is more. with tool nose radius Specific cutting energy slightly increases. For new tools, white layers only occur at aggressive feeds (=0.3 mm/rev) and small nose radius results in deeper white layers. For worn tools, white layers appear even at mild feeds (0.05 mm/rev), but in contrast, large nose radius leaves deeper white layers. Maheshwari Patil et al. 2014 [2] From this paper we focus on the effect of H.S.S. single point cutting tool nose radius on cutting edge strength and tool wear in machining of EN9.it is important to increase tool life because of cost of the cutting tool is high, so we have to pay attention to it. To understanding mechanics of turning tool geometry the effect of cutting tool geometry has long been an issue in understanding mechanics of turning tool geometry has a significant influence onchip formation, heatgeneration,toolwear and surface finishsurfaceintegrityduringturning.This paper presents a survey on variation in tool geometry that is tool nose radius, rake angle, variable edge geometry and theireffectontoolwearandcuttingedge integrity in the turning operation of components from EN9 (C45) plain carbon steel. The Heat generated during turning is affected by edge preparation due to change in work material flow around the cutting edge Tool wear had the greatest influence on magnitude of residual stress the level of microstructural alteration The result which is obtained from various testisuseful in selecting appropriate rake angle and nose radiusfor various conditions of speed, feed and depth of cut
- 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 702 which leads to economical machining and improved productivity. J. Naga Malleswara Rao et al. 2010 [3] In this experiment new type of dynamometer to measure radial of a component of cutting force using strain gauges. Dynamometer is used to measure the cutting force in any metal cutting process. The working principle of dynamometer is calibrated and readings are obtained andspecimenistestedforperformance.It is mostly used in roller burnishing process on aluminum work piece under various conditions in rollers burnishing process, a hard roller is pressed against a rotating cylindrical workpieceandparallelto the axis of the work piece on lathe. From different lubricant applications in roller burnishing operation Optimum values of burnishing force and the corresponding surface roughness value (Ra) are obtained. This dynamometer can be manufacturedata low cost. This dynamometer can be used for tests on lathe in metal cutting laboratories and engineering colleges. Variation in depth of cut can’t influence of the corner radius on the cutting forces. B.Tulasiramarao1 et al. 2014 [4] The cutting force can be measure by Research focusing on a lathe tool dynamometer,thrust/Axialforceandalsofeedforceby usingstraingaugeaccelerometerhasbeenStudied.The dynamometer applied in this experiment is a 500kg force 3-component system. To a data acquisition system the dynamometer is to be connected. Whenthe tool comes in contact with the work piece the different forces are produces and they can capture and transformed into numerical form system. In these experiment different forces for four various materials and the materials used in this project are aluminum, brass; mild steel & nylon have been noted down. The variation in depth of cut is studied by the forces on these different materials with it. Forces vary due to variation in depth of cut are shown by Graphical representation. Moaz H. Ali et al. 2014 [5] In this work, they are focusing to use a wide range of tools and techniques to ensure that the designs they are created it saves. Sometimes accidents happen when they are work in the laboratories or factories. To know success industries need to know whether a product failed or how much percentage need. 4. CONCLUSIONS After reviewing much paper related to nose radius, rack angle, feed rate etc. They can be affected the cutting force and surface roughness from above study it is clear that tool nose radius is a most important parameter in single cutting point tool. The result obtaining from the various literature surveys the following conclusion is state- 1. As a nose radius may be increased then effect on cutting force also get increases. 2. Surface roughness gets decreases with respect to increasing in nose radius. 3. Increase in feed rate can also increase the surface roughness. ACKNOWLEDGEMENT It is a pleasure for us to present this paper where guidance plays an invaluable key and provides a concrete platform for completion of the paper.
- 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 703 We would also like to thank our internal guide Asst. Prof. S. B. Deokar Department of Mechanical Engineering, for his valuable encouragement and constant scrutiny without which we wouldn’t have looked deeper into our work and realized both our shortcomings and our feats. This work would not have been possible without him. REFERENCES [1] Y. Kevin Chou, Hui Song, Tool nose radius effects on finish hard turning, Journal of Materials Processing Technology 148, 2004, pp. 259–268. [2] Maheshwari Patil, Dr. R. J.Patil, StudyEffectofHSS Single Point Cutting Tool Nose Radius on Cutting Edge Strength andToolWearinMachiningofEN9, International Journal of Science and Research (IJSR), 12, December 2014, Volume 3, pp. 2563- 2567. [3] J. Naga Malleswara Rao, A. Chenna Kesava Reddy and P.V. Rama Ra, Design and fabrication of new type of dynamometer to measure radial component of cutting force and experimental investigation of optimum burnishing force in roller burnishingprocess,IndianJournalofScience and Technology, July 2010, Vol. 3 No. 7. [4] B. Tulasiramarao, Dr. K.Srinivas,Dr.PRamReddy, A.Raveendra and Dr. B. V. R. Ravi Kumar, Finding Cutting Forces While Turning Aperation on Lathe Machine at Different Depth of Cut of Different Metals, International Journal of Innovative Research in Science, Engineering andTechnology, oct 2014, Vol. 3 pp. 16867-16872. [5] Moaz H. Ali, M. N. M. Ansari, The Effect of Nose Radius on Cutting Force and Temperature during Machining Titanium Alloy (Ti-6Al-4V), International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering, 2014, Vol:8, No:12 pp. 2124- 2127.