Stone Surface Finish with Process Parameters

International Journal of Advanced Engineering, Management and Science (IJAEMS) [Vol-2, Issue-8, Aug- 2016]
Infogain Publication (Infogainpublication.com) ISSN : 2454-1311
www.ijaems.com Page | 1266
Stone Surface Finish with Process Parameters
B.Nageswararao1
, B.Akhil2
1
AVN Institute of technology, Thiruvananthapuram, Kerala, India
2
ACE College of engineering, Thiruvananthapuram, Kerala, India
Abstract— The experiments were conducted to study and
analyze the process of granite machining operations. The
machines used for conducting the experiments are 1.35
meter diameter blade machine, 1.20 meter diameter
blade machine and 1.00 meter diameter blade machine.
Experiments were conducted to find out the power
consumed during the granite cutting, time taken to cut the
blocks, tool wear, temperature and surface finish by using
seven coolants viz., 1) Water 2) Water +Cutting oil 3)
Water + SURF1 powder 4) Water + SURF2 powder 5)
Water + SURF3 6) Kerosene 7) Diesel, by changing the
cutting parameters like speed, feed, depth of cut etc.
In granite machining operation, the machining time,
the production efficiency, the tool life, and surface finish
are to be improved by using high viscous coolants. Among
all the above coolants water + SURF1 washing powder is
the best coolant with respect to cost of production.
Keywords— Machining, Wear, Tool life, Coolant
Granite, Production.
I. INTRODUCTION
Stone was conceptualized to upgrade the technology level
of Indian stone industry, develop international market for
Indian stones and introduce the state of art mining
techniques with low environment pollution. In the present
work, different techniques and machines are used to
analyze the various parameters and studied how these,
parameters can change and behave in granite machining.
II. PROCEDURE
A model is designed to get high quality surface finish by
taking the process parameters like cutting speed, feed, depth
of cut, coolants etc. As a part of this the power
consumption, surface finish, temperature, tool wear are
measured.
Fig.4.1: Showing Line Diagram of Experimental Set Up
In experimental setup as shown in figure 4.1, the block is
placed on the moving trolley which is driven by 15HP
motor. The power was displayed in the wattmeter. The
temperature at the cutting zone was measured by a
sheathed thermo-couple. The thermo-couple of the two
wires were arranged in between the two cut strips at the end
of the block. Tool wear was measured by Vernier callipers
before consumed and after consumed. The surface
roughness was measured by portable surface roughness
meter individually. The viscosity of the cutting fluids was
measured by redwood viscometer.
Fig 4.2: Showing Experimental Set Up

International Journal of Advanced Engineering, Management and Science (IJAEMS)
Infogain Publication (Infogainpublication.com
www.ijaems.com
Experiments were conducted on 1.4met dia blade machine
like:
(a) 1.4 meter diameter blademachine
On each machine, machining of 10 samples of granite of 1m
x 0.3m (soft block) machining was done. Initially water is
taken as coolant and average values of machining time,
surface roughness, tool wear are noted. Experiments were
repeated with the following different coolants: 1) water
2) water + cutting oil, 3) Water + SURF1 Washing Powder,
4) water + SURF2 POWDER, 5) water + surf3, 6) kerosene
and 7) diesel oil has been used as coolant and the
corresponding values are measured.
The coolants are given below in the ascending
their viscosity
1. Water = 1.0 millipoise
2. Water +Cutting oil =1.35 millipoise
3. Water + SURF3washing powder =1.4
millipoise
4. Water +SURF1 = 1.8 millipoise
5. Water+ Surf3 powder =1.85
6. Kerosene = 2.20 millipoise
7. Diesel oil = 2.6 millipoise
More commonly water is used as a coolant. With water as
coolant heat is generated more due to friction.
surface roughness, temperature, tool wear increases and
leads to reduction in tool life.
VISCOSITY MEASUREMENT
Viscosity can be measured
redwood viscometer.
Viscosity can be compared with water as a
standard fluid.
Fig.4.3: Red wood viscometer
TEMPERATURE MEASUREMENT
Temperature can be measured by sheath thermo
couple. Two wires of thermo couple are inserted in
International Journal of Advanced Engineering, Management and Science (IJAEMS)
Infogainpublication.com)
on 1.4met dia blade machine
machine
samples of granite of 1m
x 0.3m (soft block) machining was done. Initially water is
taken as coolant and average values of machining time,
surface roughness, tool wear are noted. Experiments were
repeated with the following different coolants: 1) water
2) water + cutting oil, 3) Water + SURF1 Washing Powder,
4) water + SURF2 POWDER, 5) water + surf3, 6) kerosene
and 7) diesel oil has been used as coolant and the
ascending order of
millipoise
washing powder =1.4
millipoise
powder =1.85 millipoise
oolant. With water as
is generated more due to friction. As a result
temperature, tool wear increases and
with instrument
Viscosity can be compared with water as a
4.3: Red wood viscometer
Temperature can be measured by sheath thermo
couple. Two wires of thermo couple are inserted in
between parallel ends of the pieces of the block
surface.
Fig.4.4 : Sheathed thermocouple
SURFACE ROUGHNESS MEASUREMENT
Roughness can be measured by
surface meter TR100. Instrument is kept on the
work piece and the button is pressed to get the
value of surface roughness in micrometer.
Fig.4.5: Portable Surface Meter TR100
POWER MEASUREMENT
Power (in kW) can be measured by wattm
Fig.4.6: wattmeter
[Vol-2, Issue-8, Aug- 2016]
) ISSN : 2454-1311
Page | 1267
between parallel ends of the pieces of the block
: Sheathed thermocouple
SURFACE ROUGHNESS MEASUREMENT
Roughness can be measured by digital portable
surface meter TR100. Instrument is kept on the
work piece and the button is pressed to get the
value of surface roughness in micrometer.
: Portable Surface Meter TR100
POWER MEASUREMENT
Power (in kW) can be measured by wattmeter.
4.6: wattmeter

TOOL WEAR MEASUREMENT
Tool wear in mm measured by Digital Vernier calipers with Least count of 0.01mm
Fig.4.7 : Digital Vernier calipers
In existing system water as coolant obeys Taylor’s equation
to find tool life, machining time, surface roughness,
temperature, tool wear.
But in the proposed system Taylor equation is
modified
Where,
R (viscosity ratio) = viscosity of fluid/viscosity of water V
=Blade speed (m/min)
d = depth of cut (m) f = feed (m/min)
n = index depends on material, machine, cutting tool and
cutting conditions. Average process parameters
III. EXPERIMENTAL ANALYSIS
AVERAGE PROCESS PARAMETERS
S.
No
Viscosity
of coolant
Length of
piece
(m)
Machining
time
(min)
Depth of
cut
(m)
Feed rate
(m/mi n)
Power
(kW)
temperature
(ºC)
Surface
roughness
(µm)
Tool wear
(mm)
Tool life
Experime
ntal
(min)
Tool life
predicted
(min)
1 Water (1.00) 1.06 12.85 0.30 0.0824 1.86 437 6.20 0.029 8862 8862
2
Water
+ Oil (1.35)
1.08 12.10 0.30 0.0892 1.86 421 5.10 0.023 11051 10521
3
Water
+
Nirma (1.80)
1.10 10.15 0.30 0.1084 1.78 417 4.15 0.017 12125 11941
4
Water
+ ETA (1.40)
1.08 11.95 0.30 0.0903 1.74 420 5.14 0.021 11380 11321

5
Water
+surf excel
(1.85)
1.10 10.05
0.3
0
0.109
4
1.6
0
416 4.10 0.016 12563 12348
6
Kerose ne
(2.20)
1.10 9.25 0.30 0.1189 1.44 416 4.10 0.014 13214 13511
7 Diesel (2.60) 1.06 9.15 0.30 0.1158 1.33 402 4.05 0.012 15250 16395
IV. CONCLUSION
It is observed that machining time decreases, temperature,
surface finish increases, tool wear decreases cutting speed
increases, feed increases and the depth of cut also increases
while working with viscous coolants.
REFERENCES
[1] Bukkanvala Tools, Rajasthan
[2] High hang high, China
[3] Metal Cutting by R.K.Jain
[4] Machine Tools by Raghuvamsi
[5] Production Technology by Hazra Chowdary
[6] Manufacturing Technology

Stone Surface Finish with Process Parameters

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