860 876 Ramanchandran - Paper New PDF

Journal of Advanced Research in Dynamical and Control Systems Vol. 9.
Sp 2 / 2017
COMPARATIVE ASSESSMENT OF WIPER AND CONVENTIONAL

TOOL INSERTS IN DRY TURNING OF AISI 310 STAINLESS STEEL
P.Ramachandran, K. Umanath, A.R.Sivaram, K.Srividhya, and *R.Rajavel
Department of Mechanical Engineering, Faculty of Engineering, AMET University, Chennai, Tamilnadu, India
*Corresponding author. E-mail address: rajavelmech@gmail.com
ABSTRACT
Turning is a material removal process to produce rotational parts by removing unwanted
material. This paper investigates on turning of AISI 310 Stainless Steel using wiper inserts and
conventional inserts to analyze the effect of cutting speed, feed and constant depth of cut on
cutting force, surface roughness and chip morphology in a CNC lathe. The cutting forces and
surface roughness are measured on the machined surface using dynamometer and surface
roughness tester. Comparison of wiper insert and conventional insert are done to check the
considerable reduction in cutting force and surface roughness.
Keywords: Turning, AISI 310alloy, Stainless steel, Wiper Insert, Machining
INTRODUCTION
Machining is a process of material removal on a work piece and machinability of the material
defined in terms of Surface finish, Tool life, Force and power requirement and Chip control.In
this paper experimental investigation on turning of AISI 310 Stainless Steel using wiper inserts
and conventional inserts are carried out. Stainless Steel is steel alloy with a minimum of 10.5%
chromium content by mass. Some of the properties of stainless steel are, high corrosion
resistance, high work hardening rate, high cryogenic toughness, ductility is high and Lower
maintenance.AISI 310 Stainless Steels has excellent high temperature properties with good
ductility and weldability.It is designed for high temperature service.It resists oxidation in
continuous service at temperatures up to 1150C provided reducing sulphur gases are not
present. It is also used for intermittent service at temperatures up to 1040C.
JARDCS Special Issue on Allied Electrical And Control Systems 860

Journal of Advanced Research in Dynamical and Control Systems Vol. 9. Sp 2 / 2017
Like other austenitic grades these have excellent toughness, even down to cryogenic
temperatures, although other grades are normally used in this environment. Grade 310L (and
proprietary versions of this grade), is a 0.03% maximum carbon version of 310, sometimes used
for very specific corrosive environments, such as urea production. Mohamed Elbahet
al.,(1)compared the surface roughness of conventional insert and wiper insert of AISI 4140
hardened steel.JagadaleAmitkumarHanamantraoet al.,(2)found that thewiper inserts leads to
significantly improved surface roughness.and Increase in depth of cut increases the surface
roughness for both the inserts.Zhanqiang Liu et al., (3)found that conventional insert and wiper
insert presented the same trend of surface roughness increasing with the feed rate.EstevesCorreia
et al.,(4)concluded that the high feed rate of conventional inserts present high values of surface
roughness when compared with wiper inserts.Gaitonde et al., (5) analyzed the effects of depth of
cut and machining time on turning of high chromium AISI D2 cold work tool steel with CC650,
CC650WG and GC6050WH ceramic inserts.Grzesik et al., (6) reported some important
characteristics of the surface roughness produced in the turning of a hardened low chromium
alloy steel using mixed aluminatitanium carbon (TiC) ceramic cutting tools equipped with both
conventional and wiper inserts.Guddat et al.,(7) investigated the effect of wiper PCBN inserts on
surface integrity and cutting forces in finishing by hard turning of through hardened AISI
52100.WojciechStachurski et al.,(8)experimentaly found that the use of wiper inserts produces a
considerable reduction of roughness of the surface as compared to inserts with a conventional
corner geometry. Tugrulozel et al., (9) carried out neural network based predictions of surface
roughness and tool flank wear in aisi d2 and compared with a non training experimental
data.Srithar et al.,(10)investigated and found that The gradual increase of feed rate and depth of
cut increases the surface roughness in machining of AISI D2 steel by coated carbide
insert.Agustina et al.,(11) found that the cutting forces during the machining can be considered
as an index to evaluate the machinability of a material due to the fact that the magnitude of
cutting forces are strongly related to the amount of heat in the cutting area, tool wear, quality of
machined surface and accuracy of the workpiece.CatalinFetecauet al.,(12) Thus good
machinability indicates good surface finishand integrity, long tool life, low force and power
requirement, and type of chip that does not interface with the machining operation and easy to
collect.
WIPER TOOL INSERTS

Wiper inserts are capable of turning at high feed rates without losing the capability for
generating good surface finishes or chip breaking ability. Designed to smooth the surface
generated as the insert is fed along a workpiece, the wiper effect is primarily designed for
straight-line turning and facing. Surface finish in turning operations depends on a variety of
factors. Feed rate and the size of an inserts nose radius are considered to be the most influential
of these. The traditional understanding has been that Ra increases with increased feed rate and
decreases with a larger nose radius.This has become less absolute in recent years, with the
introduction of wiper inserts designed for high feed finishing. The unique geometries of these
inserts reduce the tradeoff between surface quality and feed rates, allowing for highly productive
machining of fine surface finishes.
Figure 1.1 Comparison of inserts with conventional geometry (a) and wiper geometry (b) Symbols: f-
feed; ap-depth of cut; re-radius of the cutting edge; re1 and re2-radii of wiper curvature; rbo-radius
of smoothing part; Rz-valley-to-peak height.

METHODOLOGY
SELECTION OF MATERIAL AND TOOLING
For this paper two types of tool inserts of CNMG120408 (Conventional insert) with nose radius
0.8 and CNMG120408FR (Wiper insert) were used.The nominal chemical composition of AISI
310 Stainless Steels withexcellent high temperature properties with good ductility and
weldability is presented in Table 1.1
Element Fe C Cr Ni Cu Mn Si P
Max Max Max Max
Weight Bal 0.25 24.00- 19-22 2.50- 2.0 1.5 0.045

(%) 26.00 4.50

Table 1.1, Chemical composition of AISI 310 stainless steel
PROCESS VARIABLES AND RESPONSES
The final surface finish of workpiece depends on the material of the component and cutting
parameters employed: cutting speed, feed rate, depth of cut, kind of cutting tool (geometry,
coating of the tool, etc), wear of the tool, lubrication, etc. Nevertheless, there is some lack of
agreement in the literature regarding the specific tendency of surface roughness comparison with
wiper inserts and conventional inserts with each cutting parameter (feed and cutting speed) and
there is not much literature about the effect of tool geometry.In this work, it has been studied the
effect on the final surface roughness and cutting force in AISI 310 Stainless Steel of cutting
speed, feed and tool nose radius of the cutting tool. There was a set of experiment to study effect
of cutting speed and feed on surface roughness and cutting force.
Exp.No Cutting Feed rate Depth of cut Diameter(mm) Speed(rpm)

Speed f(mm/rev) d(mm)
Vc(m/min)
1. 100 0.05 0.5 25 1273
2. 100 0.1 0.5 25 1273
3. 100 0.15 0.5 25 1273
4. 150 0.05 0.5 25 1910
5. 150 0.1 0.5 25 1910
6. 150 0.15 0.5 25 1910
7. 200 0.05 0.5 25 2546
8. 200 0.1 0.5 25 2546
9. 200 0.15 0.5 25 2546
Table 1.2 Machining Parameter and their levels at const. doc =0.5 mm
MACHINING AND TESTING

Theturning operation of AISI 310 Stainless Steels with CNMG120408 and CNMG120408FR

tool inserts are done using CNC turning machine tool in fig 1.1has followingspecification
shown in the table1.3, and the testing is done using surface roughness tester shown in the fig 1.2.
Maximum Swing dia 330mm
Max Swing one slide dia 136mm
Max. Turning dia 136mm
Max. Turning length 150mm
Travel x-axis-230mm
y-axis-230mm
Spindle speed 45-4500 rpm
Spindle motor power 7.5 Kw
No. of tools 6
Feed range 0-24000mm/min
Table 1.3 Machine specification
Figure 1.1 Turning operation on CNC lathe

Figure 1.2Mitutoyo Surface Roughness Tester
RESULTS AND DISCUSSION

EXPERIMENTAL CUTTING PARAMETERS AND CORRESPONDING RESPONSE
VALUES
Surface
Exp. Cutting speed Feed rate Depth of cut Cutting Force
Roughness
No. VC (m/min) f (mm/rev) d (mm) (Fz) N
Ra (m)
1 100 0.05 0.5 83.48 0.481
2 100 0.1 0.5 105.73 0.552
3 100 0.15 0.5 110.72 0.615
4 150 0.05 0.5 72.6 0.362
5 150 0.1 0.5 90.26 0.507
6 150 0.15 0.5 95.24 0.603
7 200 0.05 0.5 70.26 0.251
8 200 0.1 0.5 80.56 0.357
9 200 0.15 0.5 89.26 0.54
Table 1.4 Experimental results of machining of AISI 310 stainless steel using Conventional Tool Inserts.

Surface
Exp. Cutting speed Feed rate Depth of cut Cutting Force
Roughness
No. VC (m/min) f (mm/rev) d (mm) (Fz) N
Ra (m)
1 100 0.05 0.5 75.89 0.215
2 100 0.1 0.5 95.25 0.237
3 100 0.15 0.5 100.65 0.243
4 150 0.05 0.5 65.4 0.122
5 150 0.1 0.5 82.05 0.142
6 150 0.15 0.5 85.03 0.199
7 200 0.05 0.5 63.87 0.106
8 200 0.1 0.5 73.9 0.137
9 200 0.15 0.5 80.41 0.184
Table1.5 Experimental results of machining of AISI 310 stainless steel using Wiper tool insert
SURFACE ROUGHNESS (Ra)
Figure 1.3 Surface Roughness Vs No. of Experiments
Surface Roughness was measured at three different locations of sample and then average values
were considered. The surface charecteristic of machined surface can be measured by parameter

like Rz- peak value or Ra- average value using Mitutoyo surface roughness tester. The table 1.4
and 1.5 shows the Ra value of machined surface using conventional insert and wiper inserts in
turning of AISI 310 stainless steel. The graph shown in the figure 1.3 indicates the change in Ra
values with different combination of cutting parameters.
SURFACE ROUGHNESS VS FEED AND CUTTING SPEED
Feed is the main factor influencing the surface roughness, as already known due to the
geometrical relations between the feed (f) and tool nose radius(r).However, in real machining
operations other cutting parameters also influence surface roughness, because of the material
behavior under large deformations.

Figure 1.4 (a-c) Surface Roughness Vs Feed and (d-f) Surface Roughness Vs Cutting Speed
Figure 1.4 (a), (b), (c), (d), (e) and (f) shows the graphical representation of surface roughness
against the feed and cutting speed respectively for a constant depth of cut 0.5mm. The wiper
inserts are designed with modified nose radii with larger corners or flatter forms into the straight
minor cutting edge to wipe the surface smooth. The corner or flatter form of the wiper insert
indicates that it takes off more material with the back of the insert as it cuts (wipes). So the feed
rate can be approximately doubled while maintaining a similar surface finish.
CUTTING FORCE
Mounting of tool dynamometer allows direct measurement of turning forces to which it is

subjected. The tool to be examined is mounted on the cover plate of the dynamometer. The

dynamometer measures the reaction forces on the rotating workpiece via the tool. The cutting
force was measured using a Kistler piezoelectric dynamometer. The graph shown in the figure
1.5 indicates the variation in cutting force with different combination of cutting parameters.
Figure 1.5 Surface Roughness Vs No. of Experiments
CUTTING FORCE VS FEED AND CUTTING SPEED

Figure 1.6 (a-c) Cutting Force Vs Feed and (d-f) Cutting Force Vs Cutting Speed
Figure 1.6 (a), (b), (c), (d), (e) and (f) are shows the graphical representation of cutting force
against the feed and cutting speed respectively for a constant depth of cut 0.5mm. It can be seen
that the cutting force increase with increase in feed rate because of the fact that with increase in
feed shear plane area of the chip increases and forces required for cutting increases and also the
tool wear and temperature in machining increases. It was observed that at low cutting speed, the
forces were found to be higher because of the chip remains for long time in the rake face of the
tool and which increases the tool-chip contact length. Therefore, it increases the friction between
the tool and chip that resulted in higher forces. Similarly, while turning at higher cutting speed,

the temperature generation rate is high which makes the material soft at cutting zone and helps in
removing the material at lower cutting forces.
CHIP MORPHOLOGY
Exp no. Conventional Tool Wiper Tool Inserts
Inserts

Figure 1.7 Chip Morphology
Figure 1.7 shows the chips produced while machining of AISI 310 stainless steel. From exp. no.

1-3 at low speed and low feed operation, helical shaped with discontinued chips formed for
conventional inserts and helical shaped with continued chips is formed for wiper inserts. From
exp. no. 4-6 at medium speed and medium feed operation helical shaped with discontinued chips
formed for both conventional inserts and wiper inserts. From exp. no. 7-9 at high speed and high
feed operation thus gives the helical shaped with continued chips formed for conventional inserts
and helical shaped with discontinued chips formed for wiper inserts.
TOOL TIP IMAGES
To explain the lower surface roughness with increasing tool wear of the conventional insert,
pictures of the worn inserts are taken, Figure 1.8 (A and B) and 1.9 (A and B). It can be seen,
that the wear pattern differs. The depth of cut, notch wear of the wiper insert is more sustained
due to the large multi-radii. The depth of cut notch wear of the conventional insert is very
smooth and can act as an unintentional multi-radius generated by the advancing wear.
A B
Figure 1.8 Tool Tip of Conventional Insert A (unused) and B (used)

A B
Figure 1.9 Tool Tip of Wiper Insert A (unused) and B (used)
CONCLUSIONS
Experimental investigation on turning of AISI 310 Stainless Steel has been performedwith wiper
inserts and conventional inserts in order to analyze the effect of cutting speed, feed and constant
depth of cut on cutting force, surface roughness and chip morphology in a CNC lathe. The
Cutting force induced while using wiper inserts is less than the conventional inserts,Wiper
cutting insert showed better performance compared with conventional insert in the surface
roughness of the work piece. Wiper inserts reduces the tool nose wear compared to conventional
tool insertsare the conclusions made from the results obtained which are discussed above. Thus
wiper inserts are desirable for achieving a better surface finish and lower cutting force as
compared with conventional insert.
REFERENCES
1. Mohamed Elbah et al., (2013) Comparative Assessment of Wiper and Conventional
Ceramic Tools on Surface Roughness in Hard Turning AISI 4140 Steel.
2. JagadaleAmitkumarHanamantrao and Jadhav B. R. (2014) Comparison between the
Surface Roughness Criteria (Ra) of the Wiper Inserts with Conventional Inserts during
Hard Turning of En-9 Hardened Steel.

3. Zhanqiang Liu et al., (2011) Surface Roughness in High Feed Turning with Wiper Insert.
4. EstevesCorreia and J.PauloDavim, (2011) Surface Roughness Measurement in Turning
Carbon Steel AISI 1045 using Wiper Inserts.
5. Gaitonde et al., (2009) Machinability Investigations in Hard Turning of AISI D2 Cold
Work Tool Steel with Conventional and Wiper Ceramic Inserts.
6. Grzesik and T.Wanat, (2006) Surface Finish Generated in Hard Turning of Quenched
Alloy Steel Parts using Conventional and Wiper Ceramic Inserts.
7. Guddat et al., (2011) Hard Turning of AISI 52100 using PCBN Wiper Geometry Inserts
and the Resulting Surface Integrity.
8. WojciechStachurski et al., (2013) Inuence of Cutting Conditions in Turning with Wiper
Type Inserts on Surface Roughness and Cutting Forces.
9. TugrulOzel et al., (2007) Modelling of surface finish and tool flank wear in turning of
AISI D2 steel with ceramic wiper inserts
10. Srithar et al., (2014) Experimental Investigation and Surface roughness Analysis on Hard
turning of AISI D2 Steel using Coated Carbide Insert.
11. Agustina et al., (2013) Experimental Analysis of the Cutting Forces Obtained in Dry
Turning Processes of UNS A97075 Aluminium Alloys
12. CatalinFetecau and Felicia Stan, (2012)Study of cutting force and surface roughness in
the turning of polytetrafluoroethylene composites with a polycrystalline diamond tool.

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Journal of Advanced Research in Dynamical and Control Systems Vol. 9.

COMPARATIVE ASSESSMENT OF WIPER AND CONVENTIONAL

*Corresponding author. E-mail address: rajavelmech@gmail.com

Keywords: Turning, AISI 310alloy, Stainless steel, Wiper Insert, Machining

JARDCS Special Issue on Allied Electrical And Control Systems 860

WIPER TOOL INSERTS

JARDCS Special Issue on Allied Electrical And Control Systems 861

JARDCS Special Issue on Allied Electrical And Control Systems 862

SELECTION OF MATERIAL AND TOOLING

Weight Bal 0.25 24.00- 19-22 2.50- 2.0 1.5 0.045

JARDCS Special Issue on Allied Electrical And Control Systems 863

Table 1.1, Chemical composition of AISI 310 stainless steel

PROCESS VARIABLES AND RESPONSES

Exp.No Cutting Feed rate Depth of cut Diameter(mm) Speed(rpm)

1. 100 0.05 0.5 25 1273

2. 100 0.1 0.5 25 1273

3. 100 0.15 0.5 25 1273

4. 150 0.05 0.5 25 1910

5. 150 0.1 0.5 25 1910

6. 150 0.15 0.5 25 1910

7. 200 0.05 0.5 25 2546

8. 200 0.1 0.5 25 2546

9. 200 0.15 0.5 25 2546

MACHINING AND TESTING

JARDCS Special Issue on Allied Electrical And Control Systems 864

Maximum Swing dia 330mm

Max Swing one slide dia 136mm

Max. Turning dia 136mm

Max. Turning length 150mm

Spindle speed 45-4500 rpm

Spindle motor power 7.5 Kw

Feed range 0-24000mm/min

Table 1.3 Machine specification

Figure 1.1 Turning operation on CNC lathe

JARDCS Special Issue on Allied Electrical And Control Systems 865

Figure 1.2Mitutoyo Surface Roughness Tester

RESULTS AND DISCUSSION

1 100 0.05 0.5 83.48 0.481

2 100 0.1 0.5 105.73 0.552

3 100 0.15 0.5 110.72 0.615

4 150 0.05 0.5 72.6 0.362

5 150 0.1 0.5 90.26 0.507

6 150 0.15 0.5 95.24 0.603

7 200 0.05 0.5 70.26 0.251

8 200 0.1 0.5 80.56 0.357

9 200 0.15 0.5 89.26 0.54

JARDCS Special Issue on Allied Electrical And Control Systems 866

1 100 0.05 0.5 75.89 0.215

2 100 0.1 0.5 95.25 0.237

3 100 0.15 0.5 100.65 0.243

4 150 0.05 0.5 65.4 0.122

5 150 0.1 0.5 82.05 0.142

6 150 0.15 0.5 85.03 0.199

7 200 0.05 0.5 63.87 0.106

8 200 0.1 0.5 73.9 0.137

9 200 0.15 0.5 80.41 0.184

SURFACE ROUGHNESS (Ra)

Figure 1.3 Surface Roughness Vs No. of Experiments

JARDCS Special Issue on Allied Electrical And Control Systems 867

SURFACE ROUGHNESS VS FEED AND CUTTING SPEED

JARDCS Special Issue on Allied Electrical And Control Systems 868

Mounting of tool dynamometer allows direct measurement of turning forces to which it is

JARDCS Special Issue on Allied Electrical And Control Systems 869