World Academy of Science, Engineering and Technology

International Journal of Mechanical and Mechatronics Engineering

Vol:7, No:10, 2013

Theoretical and Experimental Analysis of Hard

Material Machining
Rajaram Kr. Gupta, Bhupendra Kumar, T. V. K. Gupta, D. S. Ramteke

and advances in their machining.

Abstract—Machining of hard materials is a recent technology for In machining of titanium and nickel based alloys, computer
direct production of work-pieces. The primary challenge in simulation and machining tests can greatly reduce the number
machining these materials is selection of cutting tool inserts which of expensive design iterations by bracketing the optimal
facilitates an extended tool life and high-precision machining of the ranges of process parameters. Today, hard turning has
component. These materials are widely for making precision parts for
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:10, 2013 waset.org/Publication/10001076

the aerospace industry. Nickel-based alloys are typically used in replaced the grinding processes of hardened steel components
extreme environment applications where a combination of strength, in practice [2], [3]. Machining of the hardened steels can be
corrosion resistance and oxidation resistance material characteristics achieved using super-hard cutting tool materials such as cubic
are required. The present paper reports the theoretical and boron nitride (CBN) tools and improved ceramic tools [1].
experimental investigations carried out to understand the influence of According to the survey conducted [4], hard turning is used
machining parameters on the response parameters. Considering the for the maintenance of part accuracy and finish with the
basic machining parameters (speed, feed and depth of cut) a study has
been conducted to observe their influence on material removal rate, reduction in machining time as high as 60% compared to
surface roughness, cutting forces and corresponding tool wear. grinding process. A combination of insert nose radii and feed
Experiments are designed and conducted with the help of Central rate, hard turning can produce a better finish. The knowledge
Composite Rotatable Design technique. The results reveals that for a of cutting forces is very much essential while designing
given range of process parameters, material removal rate is favorable machine tools and cutting tools for hard machining so as to
for higher depths of cut and low feed rate for cutting forces. Low feed predict the life of these tools.
rates and high values of rotational speeds are suitable for better finish
and higher tool life. During hard machining, both material and tool are subjected
to high strain rate and temperatures which makes analytical
Keywords—Speed, feed, depth of cut, roughness, cutting force, prediction very difficult [5]. In machining hardened materials,
flank wear. strain rates (about 105) and high temperatures (about 1400°C)
in secondary deformation zone are observed [6]. The work
I. INTRODUCTION carried on AISI 4140 steels to predict the temperatures various
zones shows that the temperatures are 300 to 500°C in the
H ARD machining is one of the emerging technologies for
making direct components which can be used in various
defense applications. The process is challenging in nature for
primary zone and approximately 1000°C at the tool-chip
interface [8].
the selection of cutting tools and inserts to improve the Nickel-based alloys are typically used in extreme
machining performance without the loss and breakage of environment applications where material characteristics such
inserts during machining. Hard machining presents several as strength, corrosion and oxidation resistance are required.
advantages when compared to traditional methods which are Depending on the choice of alloy, surface temperatures range
based on finish grinding operations after the heat treatment of from cryogenic to temperatures as high as 1800oF. In general,
work-pieces. This technique offers a greater contribution machining of hard materials requires a negative rake angle to
towards sustainable manufacturing. Hard materials comprises prevent chipping of the cutting edge. A negative rake angle
of hardened steels, high-speed steels, heat-treatable steels, tool would offer predominantly compressive stress and a stronger
steels, bearing steels and chilled/white cast irons. Inconel, edge during machining [12]. Machining of hard materials
Hastelloy, Cobalt alloys for biomedical applications are also requires a small depth of cut, while comparing the force
classified as hard materials. These are highly used in components (cutting and thrust forces) thrust force is usually
automobile sectors, aerospace applications for bearing the largest in magnitude. Here, small depth of cut can be
production and also for machining of dies and molds. defined as having a ratio of depth of cut (d) to tool nose radius
Machining of hard materials aims to provide the fundamentals (r) less than one (d/r < 1) [9], [13], [14]. Here a material with
hardness of 60 HRc using CBN tools is machined and found
that thrust force is larger than cutting component and this
Rajaram Kr. Gupta and Bhupendra Kumar are senior undergraduate increases greatly with nose radius of the tool.
students in Mechanical Engineering Discipline, PDPM Indian Institute of
Information Technology Design & Manufacturing Jabalpur, India. Machining of AISI 4340 alloy steels with different hardness
T. V. K. Gupta is Visiting Faculty at PDPM Indian Institute of Information levels (35-60 HRc) using CBN tools indicated that a high
Technology Design &Manufacturing, Jabalpur, India (phone: +91- shear angle and saw tooth chip formation were produced due
9425805512, e-mail: [email protected]).
D. S. Ramteke is a Research Engineer at Mechanical Engineering to poor ductility, thus reducing the cutting forces in hardened
Discipline, PDPM Indian Institute of Information Technology Design & materials [10]. Prediction of cutting forces while machining
Manufacturing, Jabalpur, India (e-mail: [email protected]).

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 World Academy of Science, Engineering and Technology
International Journal of Mechanical and Mechatronics Engineering
Vol:7, No:10, 2013

hardened AISI H2 steel (hardness 46 HRc) using the same B. Cutting Forces
type of tools but with two different thermal properties is also Cutting force is the force generated by the motion of cutting
attempted [11] where, the inserts differ in the CBN content, tool against work-piece. Fx, Fy and Fz are the forces in in x, y
50% and 90% while performing orthogonal machining. A and z-direction respectively. The resultant force is given by,
modified Oxley’s machining theory by analytically describing
the primary and secondary heat source behavior is performed. F = FX2 + FY2 + FZ2
The surface roughness values can be determined from (4)
cutting speed, feed rate and tool’s nose radius [12]. Moreover, C. Surface Roughness (Ra)
the built-up-edge [13] and tool wear [7] can affect the qualities
The surface roughness is defined as the deviation of the
of the surface roughness. Experimentally the behavior of
actual surface topography from an ideal atomically smooth
average surface roughness for different cutting conditions and
and planer surface.
tool nose radii [14] and conducted while machining several
steel bars (AISI 1020, 1045, 4140, D2), which are harder in D.Tool Wear (hf)
nature. Some of the works carried [14] stated that the depth of Tool wear describes the gradual failure of cutting tool
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:10, 2013 waset.org/Publication/10001076

cut exerted no influence upon the roughness values and a which takes place along the surfaces where there is a relative
better finish can be obtained for harder materials has been sliding action is present. The wear reports in this paper are
reported. Case-hardened 27MnCr5 steels are investigated [15] flank wear only. Flank wear is measured in terms of width of
for surface integrity under the influence of feed rate, cutting the land. Fig. 1 shows a typical wear of an insert.
speed and tool wear. It was reported that cutting speed has less
influence on surface roughness and tool wear than feed rate.
This could be that the tools are quickly worn out after few
seconds of machining. As a consequence of this, in suitable
machining areas, surface roughness is not significantly
influenced by the cutting speed, but is mainly influenced by
the feed rate. While performing end milling of Inconel 718,
response surface methodology has been applied to optimize
surface finish and suitable machining parameters are Fig. 1 Flank Wear and Crater Wear
suggested [16].
E. Design of Experiments
This paper aims to study the effect of machining parameters
on the milling performance of high chromium and nickel The principle of experimental design refers to planning,
composition work piece material. The input parameters designing and analyzing an experiment so that valid and
considered are speed (N), depth of cut (d) and feed (Vf) while objective conclusions can be drawn effectively and efficiently.
the response parameters are material removal rate (MRR), CCRD technique is used for designing the experiments which
cutting forces (Fx, Fy & Fz), surface roughness (Ra) and flank consists of three distinct sets of experimental runs namely
wear (hf). factorial runs (2k), axial runs (2k) and central runs (3≤ nc≤ 6).
ANOVA is generally used to find the variability within a
II. THEORETICAL ASPECTS regression model and form a basis for test of significance.
Comparing the t-value, p-value significant parameters can be
A. Material Removal Rate (MRR) predicted based on the experimental values. Details of these
The experimental and theoretical material removal rates are analyses are not a part of this paper.
calculated as follows:
Measured (Experimental) MRR III. EXPERIMENTATION
A. Experimental Setup
Initial Weight – Final Weight
Machining Time The experimental setup is shown in Fig. 2. It consists of a
work piece (mechanical properties as specified in Table I) is
Calculated (Theoretical) MRR fitted to dynamometer (Model No. 9275B, Kistler make)
which is mounted on an EMCO Concept Mill 155 CNC
L machining center. The dimensions of the work piece are 181
Tm = (1)
Vf mm x 154 mm x 40 mm which weighs 8.5 Kg approximately.
A 16mm end mill cutter (T490 ELN D16-2-W16-08-C)
Vc = L × d × D manufactured by ISCAR consisting of two inserts (T490
(2)
LNMT 0804 PNR-IC810), each having four cutting edges are
Vc used. The selection of process parameters and their values are
MRR = (3) elaborated in the later part of the paper.
Tm

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International Journal of Mechanical and Mechatronics Engineering
Vol:7, No:10, 2013

B. Measurements of the Responses the surface roughness obtained while the lower limits are
The response parameters considered are MRR, forces; Ra considered according to the high speed machining values.
and hf. The MRR (theoretical
theoretical and experimental
experimental) is measured Table II gives the feasible range of process parameters for
as specified above. All the forces (Fx, Fy, Fz) are measured conducting experiments.
using an universal cutting tool dynamometer and surface
roughness is measured using a surface analyzer by TESA
RUGOSURF 10 Roughness Gauge. Fig.. 3 shows a typical
surface profile of the specimen measured.

Fig. 4 Tool wear of an insert

Coolant
Nozzle
TABLE II
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FEASIBLE RANGE OF PARAMETERS

Work-piece
Parameters Min. Value Max. Value
Coolant Rotational speed, N (rpm) 500 3500
Inserted Depth of cut, d (mm) 0.1 0.3
tool Feed rate, Vf (mm/min) 500 2000

Dynamometer B. Parametric Analysis

In order to conduct a designed experimental set based on
the CCRD, it is necessary to explore the input parameters into
Fig. 2 Experimental Setup the range [-1,1, 1]. Apart from the high and low levels, zero
level (center point) and αd (axial points) are also included in
TABLE I CCRD. In the present work, number of variables (k) has been
MECHANICAL PROPERTIES OF THE WORKPIECE M ATERIAL
taken as 3, the total required number of experiments to be
Property Value
performed in a full factorial was 20, i.e., (8 factorial + center
0.2% Proof Stress (MPa) LP 784
Impact Charpy at -40ºC ±2ºC (J) 34.3
6+ axial 6). In order to make the design rotatable, the value of
% Reduction of area 25 αd was taken as 2k/4 (for full factorial) so for a three variable
Hardness (BHN), (HRC) 302-341, 32 αd= (23)1/4 and the 6 points are (-α( d, 0, 0), (αd, 0, 0), (0, -αd, 0),
(0, αd, 0), (0, 0, -αd), (0, 0, αd) where αd=1.682.
The intermediate values of all input parameters, a linear
relation between the input and coded values are assumed using
the CCRD technique. Upon calculations for the various
process parameters, Table III I gives the coded values and
absolute values for input machining parameters.
TABLE III
CODED AND ABSOLUTE VALUES FOR INPUT PARAMETERS
Factor Levels
-αd -1 0 1 αd
N (rpm) 500 1108.09 2000 2891.91 3500
d (mm) 0.10 0.14 0.20 0.26 0.30
Fig. 3 Surface roughness profile Vf (mm/min) 500 804.05 1250 1695.95 2000

Since, the machining time is very less, so flank wear is Table IV gives the observations of the CCRD runs and the
more prominent than the crater wear. In the present study, the corresponding responses along with the resultant force
tool wear is measured in terms of flank wear
ear only. Fig. 4 gives respectively.
the image of a typical tool wear of the insert which is
measured using a USB MICROSCOPE (GSAS (GSAS-UM05). V. RESULTS AND DISCUSSION
The curves are drawn using MATLAB from the results
IV. PLAN OF EXPERIMENTS obtained from experiments no. 1, 3, 8 (rotational speeds
speed (N))
A. Exploratory Experiments 3, 12, 13 (depth of cut (d)) 3, 4, 17 (feed rate (Vf)). Each graph
The ranges of the parameters are decided based on the corresponds to a single output parameter. The variation
variati in N, d
exploratory experiments conducted considering the machine and Vf are uniformly taken along x-axis
x and the responses on
capacity and the literature available.. The upper limit of all the the y-axis
axis and are displayed together in a single graph to
parameters are restricted by overloading of the machine and facilitate comparison.

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International Journal of Mechanical and Mechatronics Engineering
Vol:7, No:10, 2013

TABLE IV
OBSERVATIONS WITH THE CCRD RUNS AND THE CORRESPONDING RESPONSES
N d Vf MRR Fx Fy Fz F Ra hf
Run
(rpm) (mm) (mm/min) (mm3/sec) (N) (N) (N) (N) (µm) (µm)
1 3500.00 0.20 1250.00 71.70 19.561 25.577 36.921 48.990 1.003 47.00
2 1108.09 0.26 804.05 59.96 32.086 50.943 44.893 75.100 1.385 65.00
3 2000.00 0.20 1250.00 71.70 31.155 45.014 47.886 72.732 1.708 70.00
4 2000.00 0.20 2000.00 114.72 37.943 62.679 65.361 98.185 2.130 90.00
5 2000.00 0.20 1250.00 71.02 30.880 43.964 46.121 70.807 1.692 69.00
6 1108.09 0.26 1695.95 126.46 47.798 109.480 79.920 143.728 2.987 116.00
7 2000.00 0.20 1250.00 72.89 33.675 47.679 48.675 76.004 1.731 72.00
8 500.00 0.20 1250.00 71.70 37.520 95.804 73.236 126.291 2.657 105.84
9 2891.91 0.14 1695.95 68.10 22.459 26.184 48.355 59.399 1.297 62.00
10 1108.09 0.14 1695.95 68.10 28.607 58.064 62.884 90.245 2.470 60.00
11 2000.00 0.20 1250.00 69.87 29.779 42.035 44.088 67.805 1.678 68.00
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:10, 2013 waset.org/Publication/10001076

12 2000.00 0.10 1250.00 35.85 13.563 24.455 36.636 46.089 1.125 44.00
13 2000.00 0.30 1250.00 107.55 36.491 60.845 53.286 88.730 1.996 90.00
14 2891.91 0.26 804.05 59.96 25.468 27.405 36.773 52.459 1.147 85.00
15 2000.00 0.20 1250.00 71.98 31.788 46.568 46.987 73.395 1.711 70.00
16 2891.91 0.14 804.05 32.28 12.105 24.275 27.013 38.282 0.619 28.00
17 2000.00 0.20 500.00 28.68 13.111 14.743 19.198 27.528 0.820 31.00
18 1108.09 0.14 804.05 32.28 11.095 27.395 34.959 45.779 0.998 38.00
19 2000.00 0.20 1250.00 70.65 30.679 42.988 45.022 69.398 1.691 68.00
20 2891.91 0.26 1695.95 126.46 26.593 43.955 45.663 68.734 1.489 67.00

A. Effect of Rotational Speed Vc = πDN (6)

Fig. 5 shows the variation in MRR at different rotational
speeds and in general, MRR remains constant with the MRR = B × d × Vf (7)
increase in the rotational speed of the cutter. This is because
that with increase in rotational speed, the rate of cutting U c × B × d × Vf = Fc × π × D × N (8)
increases while the volume remains the same along with the
machining time.
1 , keeping d and Vf constant (9)
Fc ∝
N

Fig. 5 Effect of rotational speed on MRR

Fig. 6 Effect of ‘N’ on the forces
The cutting force values decrease with increase in rotational
speed as shown in Fig. 6. The rate of cutting increases with
This shows that an increase in rotational speed lowers the
increase in rotational speed, hence cutter passes through the
forces while keeping other parameters constant, which is
work piece quickly leading to reduced forces. And the power
clearly shown in Fig. 6. The surface finish improves with
relation indicates that forces have to decrease with an increase
increase in ‘N’ as shown in Fig. 7. At low speeds a larger built
in rotational speed.
up edge (BUE) are formed and also chips are fractured readily
generating a poor surface. With increasing speed, the BUE
Power, P = U c × MRR = Fc × Vc (5)
vanishes reducing the chip fracture resulting in better finish.

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International Journal of Mechanical and Mechatronics Engineering
Vol:7, No:10, 2013

The cutting forces increase with depth of cut as the cutter

has to remove more material as indicated by (8). Fig. 10 shows
this effect which means that Fc ∝ d (for same N, Vf)
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:10, 2013 waset.org/Publication/10001076

Fig. 7 Effect of ‘N’ on the surface roughness

Fig. 10 Effect of depth of cut on Forces

The plots in Fig. 11 show that an increase in depth of cut

increases the surface roughness, as both cutting forces and
self-excited vibrations are increased which are responsible for
increased roughness and tool wear.

Fig. 8 Effect of N on the flank wear

The wear on the tool decreases with increase in rotational

speed. The trend shown in Fig. 8 is because of higher cutting
forces at low speeds creating high tool wear and poor finish.
B. Effect of Depth of Cut

Fig. 11 Effect of depth of cut on surface roughness

Fig. 9 Effect of depth of cut on MRR

The effect of depth of cut on MRR is shown in Fig. 9. It is

observed that MRR increases linearly with increase in depth of
cut as the amount of material to be removed is more and this is
Fig. 12 Influence of feed rate on MRR
also seen from (7) for a constant width and feed rate.

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C. Influence of Feed Rate Increase in feed rate increased the tool wear
we due to large
The effect of feed rate on MRR is shown in Fig Fig. 12. MRR loads acting at the tool tip because of the increased MRR. Fig.
increases linearly with increase in feed rate (7) for constant 15 shows the effect of feed rate on tool wear.
width and depth of cut. The cutting forces keep on increasing
with the increase in the feed rate because the cutting force is VI. CONCLUSIONS
directly dependent on the feed rate as per ((8 which is shown in It has been observed that high speed milling processes are
Fig. 13. feasible in presence of coolant for a certain range of rotational
speeds, depth of cuts and feed rates.
rate It reduces cutting forces,
formation of BUE, chattering, roughness, and tool wear. From
the experiments it is found that MRR increased linearly with
the increase in depth of cut and feed rate while it is not
affected with rotational speeds.
speed The increase in rotational
speed helps inn lowering cutting forces while increase in the
International Science Index, Mechanical and Mechatronics Engineering Vol:7, No:10, 2013 waset.org/Publication/10001076

feed rate and depth of cut increases

increase the same. Surface
roughness and tool wear are decreased at higher rotational
speeds and it is increased with increase in depth of cut and
feed rate. Among all the input parameters, feed rate is
observed to have more effect on MRR and rotational speed
and feed rate had equal contribution on cutting forceforces and
surface roughness while the least contribution is made by
depth of cut. This had a higher contribution on tool wear in
comparison to feed rate. A better quality surfaces are obtained
Fig. 13 Effect of feed rate
ate on forces
in the chosen range of input parameters. The surface
Fig. 14 shows that an increase in feed rate will increase roughness ranges from 1-3 3 microns which was really low as
surface roughness, this is due to chatter. far as good
ood surface is concerned.
concerned

NOMENCLATURE
N: revolutions per minute (rpm)
d: depth of cut (mm)
Vf feed rate (mm/min)
B: width of cut (mm)
D: diameter of cutter (mm)
Uc : specific energy per unit volume (J/mm3)
P: power consumed (W)
MRR: Material Removal Rate (mm3/sec)
Fx: force along x-direction
direction (N)
Fy: force along y-direction
direction (N)
Fz : force along z-direction
direction (N)
Ra: center line average surface roughness (µm)
hf: flank wear (µm)
Fig. 14 Effect of feed rate on surface roughness dc : crater depth (µm)
k: number of input factors
f: factorial runs
nc number of center runs
αd: distance of axial points from the center point in CCRD

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effect of tool thermal property-application to CBN hard turning” 2003,

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Rajaram Kr. Gupta and Bhupendra Kumar are both senior undergraduate
students of IIITDMJ. Their areas of interests are machining, CAD/CAM etc.

T. V. K. Gupta is Visiting Faculty at PDPM Indian Institute of Information

Technology Design & Manufacturing, Jabalpur, India. He obtained his
Master’s Degree from National Institute of Technology Warangal, India and
Bachelors from Nagarjuna University, India. Currently he is pursuing his
Doctoral studies from Indian Institute of Technology Kanpur, India. He has
wide experience of working with industrial consultancy for about 10 years
while working as a Research Engineer at IIT Kanpur. Current research
includes CAD/CAM, CNC machining, Unconventional Machining processes.

D. S. Ramteke holds a Master’s Degree from IIT Guwahati, India. Presently

he is working as a Research Engineer at PDPM IIITDM Jabalpur in the
Discipline of Mechanical Engineering. He has a considerable experience in
developing laboratory facilities both for Design and Manufacturing area. His
major research areas include dynamics, rotor dynamics, vibrations, force
modeling etc. He has guided a wide number of undergraduate projects for
students of both IIITDMJ and students in local engineering colleges, Jabalpur,
India.

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