PREDICTION OF TOOL LIFE AN EMPIRICAL APPROACH TOOL WEAR MONITORING

A Project Report Submitted to

AWAHARLAL NEHR! TECHNOLOGICAL !NI"ERSIT#

I$ p%rti%& 'u&'i&&me$t o' re(uireme$t) 'or %*%rd o' t+e de,ree o'

BACHELOR oF TECHNOLOGY
IN

MECHANICAL ENGINEERING
-#

D.V.Malavika M.Prathyusha P.D.Sirisha Anand

(02481A0319)
. /0123A/4125 ./0123A/4365

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!$der t+e ,uid%$ce o'

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Dep%rtme$t o' Mec+%$ic%& E$,i$eeri$, G!DLA"ALLER! ENGINEERING COLLEGE G!DLA"ALLER! 603469 :RISHNA DISTRICT ANDHRA PRADESH 0//6;0//9

G!DLA"ALLER! ENGINEERING COLLEGE G!DLA"ALLER!

DEPARTMENT OF MECHANICAL ENGINEERING CERTIFICATE

This is to certify that the project report entitle <

PREDICTION OF TOOL LIFE AN EMPIRICAL APPROACH TOOL WEAR MONITORING<is a !onafi e recor of "or# carrie o$t !y
D.V.Malavika M.Prathyusha P.D.Sirisha Anand (02481A0319)
. /0123A/4125 ./0123A/4365

(//123A/4/05

In partial f$lfill%ent of re&$ire%ents for the a"ar of the -AC e'ree in M!C
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E%&(%!!$(%& of AWAHARLAL NEHR! TECHNOLOGICAL

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PRO ECT G!IDE D%te>

HEAD OF THE DEPARTMENT

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The satisfaction that acco%panies the s$ccessf$l co%pletion of any tas# "o$l !e inco%plete "itho$t the %ention of people "ho %a e it possi!le an "hose constant '$i ance an enco$ra'e%ent cro"n all the efforts "ith s$ccess( )e "o$l li#e to ta#e this opport$nity to e*press o$r profo$n sense of 'ratit$ e to o$r !elo+e ,rincipal Dr7D7PRASAD RAO= FOR pro+i in' $s all the re&$ire facilities( )e feel elate to e*ten o$r floral 'ratit$ e to Pro'7M7 AGANNADHAM Hea of the .epart%ent- Mechanical En'ineerin'- for his enco$ra'e%ent all the "ay $rin' the analysis of the project( His annotations an criticis%s are the #ey !ehin the s$ccessf$l co%pletion of the project "or#( )e "o$l li#e to e*press o$r eep sense of 'ratit$ e an sincere than#s to Sri7S+8%m Su$d%r- for his constant '$i ance- s$per+ision an %oti+ation in co%pletin' the project "or#( 7

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The life of cutting tool in metal cutting plays an important role in the quality and cost of product. In this present study, an empirical model for the prediction of cutting tool life in turning operation is developed. The performance of the metal turning has been studied under varying operating conditions such as speed of cutting, feed rate and depth of cut. This study describes the operation of the experimental system and presents the measured data. The required turning operation is performed on a lathe machine with hardened material used as engine crank pin for work piece and H. . for cutting tool. !or developing the required empirical model, "inear #egression, "inear $ross %roduct #egression, "og Transformed "inear #egression and "og Transformed $ross %roduct #egression are employed. The values predicted from various empirical models are compared with the experimental values and concluded that which model is best fit for the ob&ective. In general, the metal turning experiments and statistical tests demonstrate that 'the empirical models developed in this work are best fit with acceptable range of deviations(. The tool wear is significantly influenced by the cutting parameters like velocity, feed and depth of cut. )irect method of detecting of detecting the tool wear using tool makers microscope is not recommended in many situations. It has been observed that as tool wear begins for the same parameters, the parameters like spindle power, cutting forces, surface roughness change abruptly. Hence the variations in these parameters indicate wear states qualitatively. In this paper some indirect methods of detecting tool wear status are proposed. * neural network model is developed to predict the spindle current and cutting forces for a given cutting parameters, so as to indicate levels of tool wear. *lso the tool wear can be indirectly estimated through finite element analysis, since the tool wear is influenced by

stresses on the tool faces. Two+dimensional orthogonal cutting model is chosen with appropriate tool and work piece boundary conditions and material combinations. The deformations at the flank face are recorded for various values of tool chip contact lengths. The results are reported in the form of graphs and tables

(%+$#D-C+(#% The primary goal of this work is to establish the process relationships for the process and to build an empirical model. This analysis focuses on the effects of the selected turning parameters on the cutting tool life in turning. The empirical models are developed to locally approximate the relationship between outputs and inputs based on collected data. The Taylor,s tool life equation (-. shows that the tool life /T, and cutting speed /0, are related to each other as, 0Tn 1 $ 2here, n+tool life exponent $+Taylor,s constant +++++++++++++++ (-.

Intelligent manufacturing systems are playing today a vital role in existing commercial $3$ systems, which allow limited manipulation of cutting conditions by users . ome of the intelligent machining tasks include adaptive control, tool condition monitoring, chatter detection and process control etc. Tool condition monitoring is a very essential step in controlling the cutting process tool wear influences the work piece surface and life of the tool. Hence it is important to measure or at least state of levels of the tool wear based on the fast information is required. 4ver the last two decades tool wear monitoring studies have been going on with respect to turning, milling and drilling operations. 5specially in turning operations the tool wear is being measured by various methods .The indirect methods of tool wear is being measured by various methods. The indirect methods of tool wear measurement are gaining importance with the help of neural network6-,78,fu99y systems 6:,;8 and finite element analysis 6<+=8.Tool wear model can be developed using neural networks with the help of experimental data like cutting parameters as inputs and surface roughness, tool wear and spindle current as well as cutting forces as outputs .In this regard >ulti sensor fusion technique is followed to obtain accurate experimental data .The neural network model, which is developed along with fu99y logic, develops the level of the current wear status with appropriate machining process models.

In this paper, tool wear experiments are conducted on a turning machine tool equipped with dynamometers and spindle current meters. The data of various cutting conditions is generali9ed with a multi layer neural network model, which can predict the spindle current requirements, and cutting forces at any cutting state, nearly to the exact values based on neural network outputs and, it is possible to state the level of tool wear. *lso the elasto+plastic finite element analysis conducted in this work reveals a relationship between the chip tool contact length and proportional flank wear in the orthogonal cutting operation.

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The basic elements of all machining operations are the following? -.2ork piece, 7.Tool and :.$hip these elements are depicted in the figure below which represent cutting action of a tool in two+ dimensional or orthogonal cutting.!or providing the cutting action ,a relative motion between the tool and the work piece is necessary.This and si9e of the component. The chemical composition relative motion can be provided by either keeping the workpiece stationary and moving the tool or by keeping the tool stationary and moving the work or by moving both in relation to one another.

The workpiece provides the parent metal, from which the unwanted metal is removed by the cutting action of the tool to obtain the predetermined shape and the physical properties of the metal of the workpiece have a significant effect on the machining operation. imilarly, the tool material and its geometry are equally significant for successful machining. The type and geometry of the chip formed are greatly effected by the metal of the work piece, geometry of cutting tool and the method of cutting, etc. $hemical composition, and the rate of flow of the cutting fluid also provide considerable influence over the machining operation. . .

C"ASS(,(CA+(#% #, C-++(%& +##"S *ll the cutting tools used in metal cutting can be broadly classified as ? -. Sin0l1 23int t33ls, i.e., those having only one cutting edge @ such as lathe

tools, shaper tools, planer tools, boring tools, etc. 7. Multi.23int t33ls, i.e., those having more than one cutting edges @ such as milling cutters, drills, broaches, grinding wheels, etc. These tools may, for the sake of analysis, be considered as consisting of a number of single point tools, each forming a cutting edge. The cutting tools can also be classified according to the motion as ? (a. "in1ar 43ti3n t33l + lathe, boring, broaching, etc. (b. $3tary 43ti3n t33ls - milling cutters, grinding wheels, etc. (c. "in1ar and r3tary t33ls + drills, honing tools, boring heads, etc. (MP#$+A%+ +!$MS Aefore proceeding further, it would be advisable to be acquainted with a few important terms related to the Beometry of single point tools. -. Shank. It forms the main body of a solid tool and it is this part of the tool which is gripped in the tool holder. 7. ,a51. It is the top surface of the tool between the shank and the point of the tool. In the cutting action the chips flow along this surface only. :. P3int. It is the wedge shaped portion where the face and flank of the tool meet It is the cutting part of the tool. It is also called nose, particularly in case of round nose tools. Aase. It is actually the bearing surface of the tool on which it is held in a tool holder or clamped directly in a tool post. ;. 11l. It is the curved portion at the bottom of the tool where the base and flank of the tool meet, as shown in !ig <. %3s1 radius. If the 5uttin0 ti2 (nose) of a single point tool carries a sharp cutting point the cutting tip is weak. It is, therefore, highly stressed during the operation, may fail or lose its cutting ability soon and produces marks on the machined surface. In order to prevent these harmful effects the nose is provided with a radius, called nose radius ) It enables greater strength of the cutting tip, a prolonged t33l li61 and a superior surface finish on the workpiece. *lso, as the planing, shaping tools,

value of this radius increases, a higher cutting speed can be used. Aut, if it is too large it may lead to 5hatt1r. o, a balance has to be maintained. Its value normally varies from C.; mm to -.= mm, depending upon several factors like depth of cut, amount of feed, type of cutting, type of tool (solid or with insert., etc. P$(%C(PA" A%&"!S #, S(%&"! P#(%+ +##"S The different angles provided on single point tools play a significant role in successful and efficient machining of different metals. * thorough study of these tool angles is, therefore, a must. The main angles provided on these tools are shown in fig and the average values of these angles for cutting different metals are given in .

-. $ak1 an0l1. It is the angle formed between the face of the tool and a plane parallel to its base. If this inclination is towards the shank, it is known as back rake or top rake. 2hen it is measured towards the side of the tool, it is called the side rake. These rake angles guide the chips away from the cutting edge, thereby reducing the chip pressure on the face and increasing the keenness of the tool so that less power is required for cutting. It is important to note that an increased rake angle will reduce the strength of the cutting edge. 2ith the result, the tools used for cutting hard metals are given smaller rake angles whereas those used for softer metals contain larger rakes. %10ativ1 rak1. The rake angles described above are called positive rake angles. 2hen no rake is provided on the tool, it is said to have a 9ero rake. 2hen the face of the tool is so ground that it slopes upwards from the point it is said to contain a negative rake. It, obviously, reduces

the keenness of the tool and increases strength of the cutting edge. uch a rake is usually employed on carbide tipped tools when they are used for machining extra+hard surfaces, hardened steel parts and for taking intermittent cuts. * tool with negative rake will have a larger lip angle, resulting in a stronger tool. *nother advantage of negative rake, particularly in case of tipped tools, is that the tendency of the chip pressure is to press the tip against the body of the tool. This is, obviously, a favourable factor for tipped tools. The value of negative rake on these tools normally varies from <D to -CD.

7. "i2 an0l1. The angle between the face and the flank of the tool is known as lip angle. It is also sometimes called the angle of keenness of the tool. trength of the cutting edge or point of the tool is directly effected by this angle. "arger the lip angle stronger will be the cutting edge and vice versa. It would be observed that, since the clearance angle remains practically constant in all the cases, this angle varies inversely as the rake angle. It is only for this reason that when harder metals are to be machined, i.e., a stronger tool is required, the rake angle is reduced and consequently the lip angle is increased. This simultaneously calls for reduced cutting speeds, which is a disadvantage. The lip angle is, therefore, kept as low as possible without making the cutting edge so weak mat it becomes unsuitable for cutting. . : . Cl1aran51 an0l1. It is the angle formed by the front or side surfaces of the tool which are ad&acent and below the cutting edge when the tool is held in a hori9ontal position. It is the angle between one of these surfaces and a plane normal to the base of the tool. 2hen the surface considered for this purpose is in front of the tool, i.e., &ust below the point, the angle formed is called front clearance and when the surface below the side cutting edge is considered the angle formed is known as side clearance angle. The purpose of providing front clearance is to allow the tool to cut freely without rubbing against the surface of the &ob, and that of the side clearance to direct the cutting thrust to the metal area ad&acent to the cutting edge.

; .$1li16 an0l1. It is the angle formed between the flank of the tool and a perpendicular line drawn from the cutting point to the base of the tool <.Cuttin0 an0l1. The total cutting angle of the tool is the angle formed between the tool

face and a line through the point, which is a tangent to the machined surface of the work at that point. 4bviously, its correct value will depend upon the position of the tool in which it is held in relation to the axis of the &ob

7. +h1 3rth303nal syst14. In this system of reference planes it is assumed that the cutting tool is operating against the workpiece. *s usual, there are three main reference planes. 4ne of these, the hori9ontal plane, contains the base of the cutting tool and is known as the Aase %lane. The second plane, which is perpendicular to the base plane, contains the principal cutting edge (c. and is called the $utting %lane. Hie third plane, which is perpendicular to both the above planes, is known as 4rthogonal %lane. This set of reference planes is known as 4rthogonal ystem of #eference %lanes and is shown in !ig ?

+##" &!#M!+$' (% C##$D(%A+! S'S+!M This system, having been adopted by *merican tandards *ssociation (*. .*., is also known as *. .* system of tool signature. *lso, because of the nomenclature of reference planes as E, F and G, some authors describe it as E + F + G %lane ystem. This system is quite convenient in describing the tool angles of a single+point cutting tool. This system of reference planeHs, together with the principal angles of a single point cutting tool, is shown in !ig. <.I. The various tool angles shown in the figure are

International ystem. !urther, because of the nomenclature (", > and 3. of the %rincipal planes ( ee !ig. <.J., it is also described by some authors as " + > +3 planes system. *s already stated earlier, the tool in this system is supposed to be operating on the workpiece. Therefore, many tool parameters are variable in this system and their actual values are effected by the tool position with regard to the workpiece in actual operation. The different tool angles in this system, as shown in !ig. <.J, are the following ? KfLC 1 %lan approach angle or %rincipal $utting edge angle or %rimary cutting edge angle or >a&or cutting edge angle or simply *pproach angle. K(Li 1 *uxiliary cutting edge angle or *uxiliary cutting angle or >inor cutting edge angle or econdary cutting edge angle E 1 *ngle of Inclination or Inclination angle a 1 4rthogonal rake angle y 1 ide relief angle (: 1 2edge angle < 1 $utting angle ( 1 y M p. oci 1 ide rake angle Fi 1 5nd relief angle %i N ide wedge angle Tool )esignation in 4# ystem

In 4# system, only the main parameters of a single point cutting tool are designated in the following order ? , Inclination angle (E., 4rthogonal rake angle (a., ide relief angle (F., 5nd relief angle (Fi., *uxiliary cutting angle (K.LO., *pproach angle (Po. and 3ose radius (QR.. Benerally, symbols for degrees and millimetres are not indicated. 5ach parameter is indicated by a number only. !or example, a cutting tool designated as C + - C + < + < + J + S C + - will have the following values of its different parameters ? E 1 CD (Inclination angle. a 1 -CD (4rthogonal rake angle. F 1 <D ( ide relief angle. Fi 1 <D (5nd relief angle. K(Li 1 JD (*uxiliary cutting angle. KOLC 1 SCD (*pproach angle. # 1 - mm (3ose radius..

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$onsider !ig, which represents an orthogonal cutting. It is a schematic representation of a shaping operation, in which the workpiece remains stationary and the tool advances into the workpiece towards the left. Thus, the metal in front of the tool gets compressed very severely, causing shear stress. This stress is maximum along a plane, called shear plane. If the material of the workpiece is ductile, the material flows plastically along the shear plane, forming the chip, which flows upwards along the face of the tool. trictly speaking, the complete plastic deformation of the metal does not take place entirely along the shear plane only, but it actually occurs over a definite area, represented by %T# in !ig. The metal structure starts getting elongated along the line %T below the shear plane and continues up to the line # above the shear plane, where its deformation is complete. The complete area represented by %T# , within which the metal deformation occurs, is known as shear 9one. !or the sake of clarity in explanation the lines %T and # are shown as exactly parallel in the diagram, but actually they may not be so. They will actually be inclined to each other such that the shear 9one contained between them will be of wedge shape, with its thicker portion near the tool and the thinner one opposite to it. This shape of the shear 9one is one of the reasons due to which the chip curls. The produced chip is very hot and its safe disposal is very necessary.

+'P!S #, C (PS The chips produced during machining of various metals can be broadly classified into the following three types. The production of any particular type will largely depend upon the type of material being machined and the cutting conditions.

-. Dis53ntinu3us 3r s1041nts

5hi2s. This type of chips are produced during

machining of brittle materials like cast iron and bron9e. These chips are produced in the form of small segments, as illustrated in !ig. <.-C. In machining of such materials, as the tool advances forward, the shear+plane angle gradually reduces until the value of compressive stress acting on the shear plane becomes too low to prevent rupture. *t this stage, any further advancement of the tool results in the fracture of the metal ahead of it, thus producing a segment of the chip. 2ith further advancement of the tool, the processes of metal fracture and production of chip segments go on being repeated, and this is how the discontinuous chips arc produced. uch chips are also sometimes produced in the machining of ductile materials when low cutting speeds are used and adequate lubrication is not provided. This causes excessive friction between the chip and a tool race, leading to the fracture of the chip into small segments. This will also result in excessive wear on the tool and a poor surface finish

on the workpiece. 4ther factors responsible for promoting the production of discontinuous chips are smaller rake angle on the tool and too much depth of cut.

7. C3ntinu3us 5hi2. *s is evident from the name, the presence of separated segmental elements is totally eliminated in this case. This type of chip is produced while machining a ductile material, like mild steel, under favorable cutting conditions, such as high cutting speed and minimum friction between the chip and the tool face. If otherwise, it will break and form the segmental chip. The friction at the chip+tool interface can be minimi9ed by polishing the tool face and adequate use of coolant. *lso, with diamond tools the friction is less. The basis of the production of a continuous+ chip is the continuous plastic deformation of the metal ahead of the tool, the chip moving smoothly up the tool face .4ther factors responsible for promoting its production are bigger rake angle, finer feed and keen cutting edge of the tool.

:. C3ntinu3us 5hi2 with built+up edge. uch a chip is usually formed while machining ductile material when high friction exists at the chip tool interface. The upward flowing chip exerts pressure on the tool face. The normal reaction 3# of the chip on the tool face (!ig.. is quite high,

and is maximum at the cutting edge or nose of the tool. This gives rise to an excessively high temperature and the compressed metal ad&acent to the tool nose gets welded to it. The chip is also sufficiently hot and gets oxidi9ed as it comes off the tool and turns blue in color. The extra metal welded to the nose or point of the tool is called built up edge. This metal is highly strain hardened and brittle. 2ith the result, as the chip moves up the tool, the built+up edge is broken and carried away with the chip while the rest of it adheres to the surface of the work piece, making it rough. )ue to the built+up edge the rake angle is also altered and so is the cutting force. The common factors responsible for promoting the formation of built+up edge are low cutting speed, excessive feed, small rake angle and lack of lubricant. Adv1rs1 16615ts 36 7uilt.u2 1d01 63r4ati3n (a. #ough surface finish on the work piece. (b. !luctuating cutting force, causing vibrations in cutting tool. (c. $hances of carrying away some material from the tool by the built+up surface, producing crater on the tool face and causing tool wear. !or avoiding the formation of built+up edge the following precautions are required ? (a. The coefficient of friction at the chip+tool interface should be minimised by means of polishing the tool face and adequate supply of coolant during the operation. ( b.The rake angle should be kept large. (c.High cutting speeds and low feeds should be employed, because at high speeds the strength of the weld becomes low. also the strength of the weld becomes low. C (P + (C)%!SS $A+(# )uring the cutting action of a metal it will be observed that the thickness of the deformed or upward flowing chip is more than the actual depth of cut. It is because the chip flows upwards at a slower rate than the velocity of the cut. The velocity of the chip flow is directly effected by the shear plane angle. The smaller this angle the slower will be the chip+flow+velocity and, therefore, larger will be the thickness of the chip. #efer to !ig. "et, imilarly, at very high temperature

"ine above discussion leads to the result that t 7 L t-. The chip thickness ratio /r, is given by ? r 1 t-Qt7 ...(<.<.

ince t7 is always greater than t-, the value of chip thickness ratio /r, is less than unity. The higher the value of /r, the better is supposed to be the cutting action. The reverse of /r,is known as chip reduction coefficient. If /k, is the chip reduction coefficient, then ? U1-Qr

*lso, by substituting the value of 0 in terms of tV and fy we get tiQt7 cos a tan K.L 1+ W+++++++++ - + t&Qt7 sin a CHIP CONTROL AND CHIP BREAKERS The chips produced during machining, specially while employing higher speeds in machining of high tensile strength materials, need to be effectively controlled. This requirement is more pronounced if carbide tipped tools are being used for machining, because in that case higher speeds will be used and, therefore, due to high temperatures the resulting chip will be continuous, of blue colour and take the shape of a coil. uch a chip, if not broken into parts and removed from the surroundings of the metal cutting area, is likely to adversely effect the machining results in one or more of the following ways ? -. It may adversely effect the tool life by spoiling the cutting edge, creating crater and raising temperature. 7. Its presence may lead to a poor surface finish on the workpiece. :. If the chip gets curled around the rotating workpiece andQor the cutting ...(<.-7.

tool, it may be ha9ardous to the machine operator. ;. If a large and continuous coil is allowed to be formed, it may engage the entire machine and even the workplace. It is quite dangerous. <. 0ery large coils offer a lot of difficulty in their removal. uch difficulties are, however, not encountered while machining materials like brass and cast iron, because in their machining continuous chips of the above type are not produced. Aut, in case of continuous chips some means must be used to overcome the difficulties and adverse effects mentioned above. !or this purpose the chip breakers are used. These chip breakers break the produced chips into small pieces. The work hardening of the material of the chip makes the work of the chip breakers easy. If the &ob requirements do not call for a very strict chip control the common methods used for chip breaking are ? (Q. Ay control of tool geometry, i.e., grinding proper back rake and side rake according to the feeds and speeds to be used. (QQ. Ay obstruction method, i.e., by interposing a metallic obstruction in the path of the coil. Aut, when a strict chip control is desired some sort of a chip breaker has to be employed. The following types of chip breakers are commonly used ? -. &r33v1 ty21 ? It consists of grinding a groove on the face of the tool, behind the cutting edge, leaving a small land near the tip, as shown in !ig. <.-; (a.. 7. St12 ty21? It consists of grinding a step on the face of the tool, ad&acent to the cutting edge, as shown in !ig. (b.. :. S153ndary rak1 ty21? It consists of providing a secondary rake on the tool through grinding, together with a small step, as shown in !ig. (c..
c

;. Cla42 ty218+his type of chip breaker is very common with the carbide tipped tools. The chip breaker is a thin and small plate which is either bra9ed to or held mechanically on the tool face, as shown in !ig . ,#$C!S #% A S(%&"! P#(%+ +##" (% +-$%(%&

It is a case of oblique cutting in which three component forces act simultaneously on the tool point, as shown in !ig. <.-J. The components are ? !t 1 The feed force or thrust force acting in hori9ontal plane parallel to the axis of the work.

!r 1 The #adial force, also acting in the hori9ontal plane but along a radius of the workpiece, i.e. along the axis of the tool. ! c 1 The cutting force, acting in vertical plane and is tangential to the work surface. *lso called the tangential force. 4ut of these three component forces, !c is the largest and !r the smallest. It has been found out that the value of ! t for turning varies between C.: !c to C.= !c and that of !r between C.7 !c to C.; !c. In case of orthogonal cutting, discussed in the previous article, only two component forces come into play since the value of !r is H9eroH in that case. In the present case of turning operation, the components !$,!t and !r can be easily determined with the help of suitable force dynamometers. Their resultant # can then be computed from the following relation @ # 1 0!$7 M !t7 M !r7 and for orthogonal cutting, . $XTTI3B %55), !55) *3) )5%TH 4! $XT $utting speed of a cutting tool can be defined as the rate at which its cutting edge passes over the surface of the workpiece in unit time. It is normally expressed in terms of surface speed in metres per minute. It is a very important aspect in machining since it considerably effects the tool life and efficiency of machining. election of a proper cutting speed has to be made very &udiciously. If it is too high, the tool gets overheated and its cutting edge may fail, needing regrinding. If it is too low, too much time is consumed in machining and full cutting capacities of the tool and machine are not utilised which results in lowering of productivity and increasing the production cost. !eed of the cutting tool can be defined as the distance it travels along or into the workpiece for each pass of its point through a particular position in unit time. !or example, in turning operation on a lathe it is equal to the advancement of the tool corresponding to each revolution of the work. However, it is computed and mentioned in different machine tools and different operations. !or ex? in planing it is the work which is fed and not the tool. # 1 v!c7 M !r7

imilarly, in milling involving the use of a multi+point cutter, the feed is basically considered per tooth of the cutter. The cutting speed and feed of a cutting tool is largely influenced by the following factors. -. >aterial being machined. 7. >aterial of the cutting tool. :. Beometry of the cutting tool. ;. #equired degree of surface finish. <. #igidity of the machine tool being used. =. Type of coolant being used. D12th 36 5ut. It is indicative of the penetration of the cutting edge of the tool into the workpiece material in each pass, measured perpendicular to the machined surface, i.e., it determines the thickness of metal layer removed by the cutting tool in one pass. !or example, in turning operation on a lathe it is given by ? )epth of cut where, 1()+d.Q7 ) 1 4riginal diameter of the stock in mm d 1 )iameter obtained after turning, in mm. S#-$C!S #, the following ? -. Ar3und sh1ar 2lan1 It is the region in which actual plastic deformation of the metal occurs during machining. )ue to this deformation, heat is generated. * portion of this heat is carried away by the chip, due to which its temperature is raised. The rest of the heat is retained by the workpiece. It is known as %rimary )eformation Gone. !A+ (% M!+A" C-++(%&

)uring metal cutting, heat is generated in three regions as shown in !ig. These regions are

7. +33l.5hi2 int1r6a51 .*s the chip slides upwards along the face of the tool friction occurs between their surfaces, due to which heat is generated. * part of this heat is carried by the chip, which further raises the temperature of the chip, and the rest transferred to the tool and the coolant. This area is known as deformation 9one. It is reckoned that the amount of heat generated due to friction increases with the increase in cutting speed. However, it is not appreciably effected with the increase in depth of cut 2hen the feed rate is increased the amount of frictional heat generated is relatively low. Aut, in that case, the surface finish obtained is inferior. :. +33l.93rk2i151 int1r6a51 . That portion of the tool flank which rubs against the work surface is another source of heat generation due to friction. This heat is also shared by the tool, workpiece and the coolant used. It is more pronounced when the tool is not sufficiently sharp. !ig shows the distribution of the heat generated during metal cutting, neglecting the heat flowing to the atmosphere. 4n an average, about ICY of the total heat is carried away by the chip, about -<Y is transferred to the tool and the remaining -<Y to the workpiece. !rom the diagram you will observe that with an increase in cutting speed a higher amount of heat is absorbed by the chip and lesser amount is transferred to the tool and the workpiece . 2) 1 $utting force (kgf. x $utting velocity (mQmin. econdary

1 !c x 0c kgf mQmin. 3ow, if T be the amount of total heat generated in cutting the metal, then ? T 1 2.)(In kgf mQmin.Q;7I 1!$Z0$Q;7I k.calQmin

+##" ,A("-$! A 2r321rly d1si0n1d and 0r3und 5uttin0 t33l is 1:215t1d t3 21r63r4 th1 41tal 5uttin0 321rati3n in an 16615tiv1 and s433th 4ann1r. (6; h391v1r; it is n3t 0ivin0 a satis6a5t3ry 21r63r4an51 it is indi5ativ1 36 th1 t33l 6ailur1 and th1 sa41 is r16l15t1d 7y th1 63ll39in0 adv1rs1 16615ts 37s1rv1d durin0 th1 321rati3n 8 1. !:tr141ly 233r sur6a51 6inish 3n th1 93rk2i151. 2. i0h1r 53nsu42ti3n 36 2391r. 3. *3rk di41nsi3ns n3t 71in0 2r3du51d as s215i6i1d. 4. #v1rh1atin0 36 5uttin0 t33l. <. A221aran51 36 a 7urnishin0 7and 3n th1 93rk sur6a51. Durin0 th1 321rati3n; a 5uttin0 t33l 4ay 6ail du1 t3 3n1 3r 43r1 36 th1 63ll39in0 r1as3ns 8 1. +h1r4al 5ra5kin0 and s36t1nin0. 2. M15hani5al 5hi22in0. 3. &radual 91ar. -. +h1r4al 5ra5kin0 and s36t1nin0. It has already been seen earlier that a lot of heat is generated during the process of metal cutting. )ue to this heat the tool tip and the area closer to the cutting edge becomes very hot. *lthough the cutting tool material is quite hard to withstand this temperature, still every tool material has a certain limit to which it can withstand the elevated temperature without losing its hardness. If that limit is crossed, the tool material starts deforming plastically at the tip and ad&acent to the cutting edge under the action of the cutting pressure and the high temperature. Thus, the

tool loses its cutting ability and is said to have failed due to softening. The main factors responsible for creating such conditions of tool failure are high cutting speed, high feed rate, excessive depth of cut, smaller nose radius and choice of a wrong tool material. The temperature ranges within which the common tool materials can successfully operate without losing their hardness are ? $arbon tool steels High speed steels $emented carbides 7CCD$ + 7<CD$ <=CD$ + =CCD$ JCCD$ + -CCCD$

4n account of fluctuations in temperatures and severe temperature gradients the tool material is sub&ected to local expansion and contraction. This gives rise to the setting up of temperature stresses or thermal stresses, due to which cracks are developed in the material. These cracks, known as Thermal cracks, emanate from the cutting edge and extend inwards. The tool failure due to this aspect is known as failure due to thermal cracking or doe to thermal stresses. uch a failure of tool is shown in !ig.

7. M15hani5al 5hi22in0. >echanical chipping of the nose andQor the cutting edge of the tool are commonly observed causes of tool failure. The common reasons for such failure are too high cutting pressure, mechanical impact, excessive wear, too high vibrations and chatter, weak tip and cutting edge, etc. * typical form of mechanical chipping is shown in !ig. This type of failure is more pronounced in carbide tipped and diamond tools due to the high brittleness of the tool material. : &radual 91ar , when a tool is in use for sometime it is found to have lost some weight or mass, implying that it has lost some material from it, which is due to wear. The following two types of wears are generally found to occur in cutting tools ? -. Crat1r 91ar. The principal region where wear takes place in a cutting tool is its face, at a small distance (say 0. from its cutting edge ( ee !ig. This type of wear generally takes place while machining ductile materials, [ steel and steel alloys, in which continuous chip is produced. The resultant for of this type of wear is the formation of a crater or a depression at the tool interface. This type of wear, or the formation of crater on the tool face, is due to the pressure of the hot chip sliding up the face of the tool. The metal from the tool face is supposed to be transferred to the sliding chip by means of the diffusion process.

The shape of the crater formed corresponds to the shape of the underside of the chip. The principal dimensions of the formed crater are its breadth /b, and depth f, as shown in !ig. * continued growth of crater will result in the cutting edge of the tool becoming weak and may finally lead to the tool failure. *t very high speed, and the consequent high temperatures (say -CCCD$., the H. . . tool will fail due thermal softening of material, while the tools made from harder materials, like those containing tungsten carbide, titanium carbide, cobalt etc., will not wear out so rapidly. Higher feeds and lack of cutting fluids increase the rate of crater wear. 7. ,lank 91ar. *nother region where an appreciable amount of wear occurs is the flank below the cutting edge. It occurs due to abrasion between the tool flank and the workpiece and excessive heat generated as a result of the same. The abrasive action is aided by the hard micro constituents of the cut material and broken parts of built+up edge, if it is there. That is why this type of wear is more pronounced while machining brittle material, because the cut chips of such materials provide a lot of abrasive material readily. The entire area sub&ected to flank wear is known as wear land. This type of wear mainly occurs on the tool nose and front and side relief faces, as shown in !ig The magnitude of this wear mainly depends upon the relative hardnesses of the workpiece and tool materials at the time of cutting operation and also the extent of strain hardening of the chip. 2hen the tool is sub&ected to this type of wear, the workpiece loses its dimensional accuracy, energy consumption is increased and the surface finish is poor.

The effect of flank wear is expressed in terms of the width (or height. of wear land, which is dependent on time. This height is a linear measure and is symbolically denoted by 0A, 2", or hf millimeters.The total flank wear consists of three main components , as shown in the graph drawn between the 91arland h1i0ht (0A. and time(t..The first component (*., which exists for a small duration, represents the period during which initial wear takes place at a rapid rate. The second segment (A., which exists for along duration, represents the period during which the wear progresses uniformly. The last segment ($. represents the region in which wear occurs at a very rapid rate and results in total failure of the tool. That is why this region is also known as the period of destructivewear.

It is suggested that the tool be reground before the flank wear eaters the last segment ($. for which some definite value of 0A (say C.< mm. is specified as the limiting value of flank wear such that the cutting tool must be reground before this value is attained by 0A. Table below provides the limiting values of flank wear+for

different tool and work material combinations under given cutting conditions. This can serve as a useful guide for the selection of flank wear criterion. !lank wear criterion in cutting tools Tool material 2orkpiece material H. . . H. . . $emented carbide $emented carbide $eramic $ast iron $ast iron or steel . M!C A%(SM #, *!A$ The wear mechanism of cutting tools is a very complex phenomenon. However, the common mechanisms supposed to be responsible for causing wear are the following? -. A7rasi3n. It is a type of mechanical wear. Xnder this mechanism, hard particles on the underside of the sliding chip, which are harder than the tool material, plough into the relatively softer material of the tool face and remove metal particles by mechanical action. The material of the tool face is softened due to the high temperature. The hard particles present on the underside of the chip may be ? (a. !ragments of hard tool material. (b. Aroken pieces of built+up edge, which are strain hardened. (a. 5xtremely hard constituents, like carbides, oxides, scales, etc., present in the work material. 7. Adh1si3n. Ay now, it should have been quite clear that due to the excessive pressure a lot of friction occurs between the sliding surface of the chip and the tool face. This gives rise to an extremely high localised temperature, causing .............. C.= !eed K C.: mmQrev. C.J to -.C teel !eed L C.: mmQrev. -.; to -,I $ast iron teel $utting conditions emi+rough emi+rough "imiting value of 0A (mm. \I to 7.C C.= to -.C

metallic bond between the materials of the tool face and the chip. A ut, an important point to be noted here is that the surfaces of both the chip underside and the tool face, although appear to be smooth apparently, are microscopically rough. Therefore, the contact between these surfaces is not truely a surface contact but a point contact, as shown in !ig. .7S. )ue to the excessively high temperature at the chip+tool interface a metallic bond takes place between the chip material and tool material at the contact points, in the form of small spot welds, as shown in the diagram. 2hen the chip slides, these small welds Hare broken. Aut this separation is not along the line of contact. * small potion of the welded tool contact is also carried away by the sliding chip. Thus, small particles from the tool face continue to be separated through this phenomenon and carried away by the chip by adhesion to its underside. The amount of material so transferred from the tool face to the chip will depend upon the contact area and relative hardness of the chip and the tool materials.

: Di66usi3n.

olid state diffusion, which consists of transfer of atoms in

a metal crystal lattice, is another cause of wear. This transfer of atoms takes place at elevated temperatures from the area of high concentration to that of low concentration. The favorable condition for diffusion is provided by the rise in locali9ed temperature over the actual contact area between the chip underside and the tool face. In such a condition, the metal atoms are transferred from the tool material to the chip material at the points of contact. This weakens the surface structure of the cutting tool and may ultimately lead to tool failure. The amount of diffusion depends upon ? (a. Temperature at the contact area between the tool face and the chip. (b. The period of contact between the tool face and ]the chip. (c. The bonding affinity between the materials of the tool and the chip.

;. Ch14i5al 91ar. This type of wear occurs when such a cutting fluid is used in the process of metal cutting which is chemically active to the material of the tool. This is clearly the result of the chemical reaction taking place between the cutting fluid and the tool material, leading to a change in the chemical composition of the surface material of the tool. +##" "(,! Q

Tool life can be defined as the time interval for which the tool works satisfactorily between two successive grindings (sharpening.. Thus, it can be basically conceived as functional life of the tool. *s already discussed earlier, the tool is sub&ected to wear continuously while it is operating. 4bviously, after some time, when (he tool wear is increased considerably, the tool loses its ability to cut efficiently and must be reground. If not, it will totally fail. The tool life can be effectively used as the basis to evaluate the performance of the tool material, assess machinability of the workpiece material and know the cutting conditions. There are three common ways of expressing tool life ? -. *s time period in minutes between two successive grindings. 7. In terms of number of components machined between two successive grindings. This mode is commonly used when the tool operates continuously, as in case of automatic machines. :. In terms of the volume of material removed between two successive grindings. This mode of expression is commonly used when the tool is primarily ^ used for heavy stock removal. The method of assessing the tool life in terms of the volume of material removed per unit of time is a practical one and can be easily applied as follows ? 0olume of metal removed per minute 1 :.-;.).t f 3 mm:Qniin where, ) 1 dia. of workpiece in mm t 1 depth of cut in mm f1 feed rate in mmQrev. 3 1 3o. of revolutions of work per minute

If T be the tune in minutes to tool failure, then ? Tola_ volume of metal removed to tool failure 1 :.-;.).t.f.3.Tmm: 2e also know that the cutting speed ., 0 1 :.-;)3Q-CCC mQmin Ay substituting this value in equation (<.=C., we get? Total volume of metal removed to tool failure 1 0x l444ZtZfZT mm : +

Therefore, tool life (T". in tenns of the total volume af the melal removed to tool failure is given by ? T" 1 0 . -CCC . t . f . T (mm :. ,AC+#$S A,,!C+(%& +##" "(,! The life of a cutting tool is affected by the following factors ? -. $utting speed 7. !eed and depth of cut :. Tool Beometry ;. Tool material <. 2ork material =. 3ature of cutting I. #igidity of machine tool and work J. Xse of cutting fluids. !,,!C+ #, C-++(%& SP!!D 4ut of all the above factors, the maximum effect on tool life is of cutting speed. The tool life varies inversely as the cutting speed, i.e., the higher the cutting speed the smaller the tool life. Benerally, the reduction in tool life corresponding to an increase in cutting speed is parabolic, as shown in !ig. Aased on the pioneer work of !.2. Taylor, the relationship between cutting speed and tool life can be expressed as ? 0T n1 $ 0 1$utting speed (m*nin.
r

T 1 Tool life (minutes. n 1 *n exponent, whose value largely depends on the material of the tool, called the life index. Xpto a certain extent, its value is also influenced by some other variables like tool material, cutting conditions, etc. $ 1 * constant, called machining constant, which is numerically equal to the cutting speed in metres per minute that would give a tool life of one minute.

+##" &!#M!+$' >any geometrical parameters (tool angles. of a cutting tool influence its performance and life.!or example $ak1 an0l1 has a mixed effect .If it is increased in a positive direction the cutting force and the amount of heat generated are reduced. 4bviously, this should help increase the life of cutting tool .Aut, if it is very large the cutting edge is weakened and also its capacity to conduct heat is reduced. Thus, a considerable increase of the positive rake results in reduction of mechanical strength of the tool and, hence, lowering of tool life. ince the above two effects are opposite to each other, for an effectively economical tool life it is necessary to strike a balance between the two, for which the optimum value of rake angle needs to be used. This value varies from + <D to M -CD. The minus sign indicates a negative rake, i.e., a rake angle made by the cutting edge sloping upwards from the tip. Tools carrying negative rake provide a stronger cutting edge and, hence, a stronger tool. $emented carbide and ceramic tools are generally provided negative rake.

imilar contradictory effects are observed with the variations in relief angles or clearance angles. These angles are provided on the cutting tools to prevent rubbing of tool flank against the machined work surface. They, thus, help in lowering the amount of heat generated and, therefore, increasing the tool life. A ut, a very large relief angle results in weakening of tool and, hence, reduction of too_ life. *gain, therefore, a balance needs to be struck and only an optimum value should be used. These angles normally vary from <D to JD, but in special cases, such as in carbide tipped tools, a higher value upto -CD can be used to prevent rubbing of shank. The two cutting edge angles also have their influence on tool performance. Tlic !ront cutting edge angle, also known as end cutting edge angle, effects the tool wear. Xpto a certain optimum value an increase in this angle permits the use of higher speeds without an adverse effect on tool life. Aut, an increase beyond that value will result in reduction of tool life. It generally varies from <D to JD. The side cutting edge angle or the plan approach angle has a complex effect on tool life. If this angle is smaller, higher speeds can be employed. * larger end cutting edge angle increases tool life.

ome other geometrical parameters effecting the tool life are ? - (n5linati3n an0l1. Tool life increases with the increase in this angle upto an optimum value. 7 %3s1 radius. 2hile it increases abrasion, it also helps in improving surface finish and tool strength and, hence, the tool life.

+##" MA+!$(A" The main characteristics of a good cutting tool material are its hot hardness, wear resistance, impact resistance, abrasion resistance, heat conductivity, strength, etc. 2hat is important to tool life is the likely changes in these characteristics at high temperature because the metal cutting process is always associated with generation of high amount of heat and, hence, high temperatures. 2e have already seen that the cutting speed has the maximum effect on tool life, followed by feed rate and depth of cut. *ll these factors

contribute to the rise of temperature. That is why it is always said that an ideal tool material is the one which will remove the largest volume of work material at all speeds. It is, however, not possible to get a truly ideal tool material. 2e, therefore, can say that the tool material which can withstand maximum cutting temperature without losing its principal mechanical properties (specially hardness. and geometry will ensure maximum tool life, and, hence, will answer the most efficient cutting of metal. 2e, therefore, conclude that the higher the hot hardness and toughness in the tool material the longer the tool life. *#$) MA+!$(A" The microstructure of the work material plays a significant role because it directly effects the hardness of the material. !or example, presence of free graphite and ferrite in cast iron and steel imparts softness to them. %earlitic structure is harder than this and the martensitic structure is the hardest. imilarly, scale formation and presence of oxide layer on the work surface serve as abrasives and, therefore, have a detrimental effect on tool life. The increase in cutting temperature and power consumption vary directly as the hardness of workpiece material. $onsequently, higher the hardness of the work material greater will be the tool wear and, therefore, shorter will be the tool life. *dverse effects on tool life are also experienced in machining of pure metals because of their tendency to stick to the tool face, specially at high temperature. This results in more friction and, hence, high amount of wear on tool and, Therefore, a shorter tool life.

%A+-$! #, C-++(%& Tool life is also effected by the nature of cutting, i.e., whether it is continuous or intermittent. In the latter case, the tool is sub&ected to repeated impact loading and may give way much earlier than expected until it is made substantially strong and tough. In continuous cutting, a similar tool will have a relatively longer life. . $(&(D(+' #, MAC (%! +##" A%D *#$) Aoth the machine tool and the workpiece should remain rigid during the machining operation. If not, vibrations will take place and then the cutting tool will be sub&ected to

intermittent cutting instead of continuous cutting. This will result in impact loading of tool and, therefore, a shorter life. -S! #, C-++(%& ,"-(DS $utting fluids are used in machining work for helping the efficient performance of the operation. They are used either in liquid or gaseous form. They assist in the operation in many ways, such as by cooling the toot and work, reducing friction, improving surface finish, helping in breaking of chips and washing them away, etc. These factors help in improving tool life, permitting higher metal removal rate and improving the quality of surface finish. )etails of the functions, properties and types of various cutting fluids are given separately in latter chapters. . C A$AC+!$(S+(CS #, C-++(%& +##" MA+!$(A"S The materials used for the manufacture of cutting tools should possess the following characteristics ? -. *bility to retain its hardness at elevated temperatures, called hot hardness. 7. *bility to resist shock, called toughness. :. High resistance to wear, to ensure longer tool life. ; "ow coefficient of friction, at the chip + tool interface, so that the surface finish is good and wear is minimum. 7. hould be cheap. H

:. hould be able to be fabricated and shaped easily. ;. If it is to be used in the form of bra9ed tips, its other physical properties like tensile strength, thermal conductivity, coefficient of thermal expansion and modulus of elasticity, etc., should be as close to the shank material as possible to avoid cracking.

+'P!S #, C-++(%& +##" MA+!$(A"S The following materials are commonly used for manufacturing the cutting tools. election of a particular material will depend on the type of service it is expected to perform. -. High $arbon teel, 7. High peed teel,

:. $emented $arbides, ;. tellite, <. $emented 4xides or $eramics, and =. )iamond. -. High carbon steel. %lain carbon steels having a carbon percentage as high as -.<Y are in common use as tool materials for general class of work. However, they are not considered suitable for tools used in production work on account of the fact that they are not able to withstand very high temperature. 2ith the result, they cannot be employed at high speeds. Xsually the required hardness is lost by them as soon as the temperature rises to about 7CCD$ + 7<CD$. They are also not highly wear resistant. They are used mainly for hand tools. They are, however less costly, easily forgeable and easy to heat treat. High carbon medium alloy steels are found to be more effective than plain high carbon steels. These steels, in addition to the carbon content at par with that in the plain high carbon steels, are provided better hot hardness, higher impact resistance, higher wear resistance, etc., by adding small amounts of tungsten, chromium, molybdenum, vandium, etc., which improves their performance considerably and they are able to successfully operate upto cutting temperatures of:<CD$. 7. High speed steel. It is a special alloy+steel which may contain the alloying elements like tungsten, chromium, vanadium, cobalt and molybdenum, etc. up to 7< per cent These alloying elements increase its strength, toughness, wear resistance, cutting ability and ability to retain its hardness at elevated temperatures in the range of <<4D$ to =CCD$. 4n account of these added properties the high speed steel tools are capable of operating safely at 7 to : times higher cutting speeds than those of high carbon steel tools. The most commonly used high speed steel is better known by its composition of alloying elements as -J + ; + -, i.e., the one that contains -JY 2, ;Y $r and -Y 0. *nother class of H. . . contains high proportions of cobalt (7 to -<Y. and is known as $obalt H. . . It is highly wear resistant and carries high hot hardness. * highly tough variety of H. . ., known as 0anadium H. . ., carries N7Y 0, =Y 2, =Y >o and ;Y $r. It is widely favored for tools which have to bear impact loading and perform intermittent cutting.

:. $emented

carbides. The every day growing demand of higher

productivity has given rise to the production of cemented or sintered carbides. These carbides are formed by the mixture of tungsten, titanium or tantalum with carbon. The carbides, in powdered form, are mixed with cobalt which acts as a Nbinder. Then a powder metallurgy process is applied and the mixture, sintered at high pressures of -<CC kg per sq. cm to ;CCC kg per sq. cm and temperatures of over -<CCD$, is shaped into desired forms of tips. These carbide tips are then bra9ed or fastened mechanically (clamped. to the shank made of medium carbon steel. This provides an excellent combination of an extra+hard cutting edge with a tough shank of the tool. These cemented carbides possess a very high degree of hardness and wear resistance. %robably diamond is the only material which is harder than these carbides. They are able to retain this hardness at elevated temperatures up to I444D$. 2ith the result, the tools tipped with cemented carbide tips are capable of operating at speeds < to = times (or more. higher than those with the high speed steels. It will be interesting to note at this stage that the best results with these tools can be obtained only when the machines, on which they are to be used, are of rigid construction and carry high powered motor so that higher cutting speeds can be employed. ;. tellite. It is a non+ferrous alloy consisting mainly of cobalt, tungsten and chromium. 4ther elements added in varying proportions are tantalum, molybdenum and Aoron. It has good shock and wear resistances and retains its hardness at red heat upto about S7CD$. 4n account of this property, it is advantageously used for machining materials like hard bron9es, and cast and malleable iron, etc. Tools made of stellite are capable of operating at speeds up to 7 times more than those of common high speed steel tools. tellite does not respond to the usual heat treatment process. *lso, it can not be easily machined by conventional methods. 4nly grinding can be used for machining it effectively. * stellite may contain ;C+<CY $o, -<+:<Y $r, -7+7<Y 2 and -+;Y carbon. $emented 4xides or $eramics. The introduction of ceramic material as a useful cutting tool material is, rather, a latest development in the field of tool metallurgy. It mainly consists of aluminium oxide, which is comparatively much cheaper than any of the chief constituents of cemented carbides. Aoron+ nitrides in powdered form are added and mixed will aluminium oxide powder and sintered together at

a temperature of about -ICCD$.They are then compacted into different tip shapes. Tools made of ceramic material are capable of withstanding high temperatures, without losing their hardness, up to -7CCD$. They are much more wear resistant as compared to the cemented carbide tools. Aut, at the same time, they are more brittle and possess low resistance to bending. 2ith the result, they cannot be safely employed for rough machining work and in operations where the cut is intermittent. .However, their application for finishing operations yields very satisfactory results. It is reckoned that, under similar conditions, the ceramic tools are capable of removing four times more material than the tungsten carbide tools with a consumption of 7C per cent less power than the latter. They can safely operate at 7+: limes the cutting speeds of tungsten carbide tools. $eramic tool material is used in the form of tips which are either bra9ed to the tool shank or held mechanically on them as the cemented carbide tips. pecially designed tool holders are also used for holding these tips. Xsually no coolant is needed while machining with ceramic tools. =. )iamond. )iamond is the hardest material known and used as cutting tool material. It is brittle and offers a low resistance to shock, but is highly wear resistant. 4n account of the above factors diamonds are employed for only light cuts on materials like bakelite, carbon, plastics, aluminium and brass, etc. Aecause of their low coefficient of friction they produce a high grade of surface finish. However, on account of their excessively high cost and the demerits narrated above, they find only a confined use in tool industry. They are used in the form of bits inserted or held in a suitably designed wheel or bar. )iamond particles are used in diamond wheels and laps .

MAC (%A/("(+' >achiability of a material gives the idea of the ease with which it can be machined. The parameters generally influencing the machinability of a material are ? -. %hysical properties of the material, 7. >echanical properties of the material, :. $hemical composition of the material, ;. >icro+structure of the material, and <. $utting conditions.

ince this property (machinability. of the material depends on various variable factors, it is not possible to evaluate the same in terms of precise numerical values, but as a relative quantity. The criteria of determining the same may be as follows ? -. +33l li61 + The longer the tool life it enables at a given cutting speed the better is the machinability. 7. Sur6a51 6inish + It is also directly proportional, i.e., the better the surface finish the higher is the machinability. :. P391r 53nsu42ti3n + "ower power consumption per unit of metal removed indicates better machinability. ;. Cuttin0 63r51s + The lesser the amount of cutting force required for the removal of a certain volume of metal or the higher the volume of metal removed under standard cutting forces the higher will be the machinability. <. Sh1ar an0l1 + "arger shear angle denotes better machinability. =. #ate of metal removal under standard cutting conditions. <.41. MAC (%A/("(+' (%D!= *s mentioned in the previous article, the 4a5hina7ility of a material is a relative quantity. The machinabilities of different materials are compared in terms of their 4a5hina7ility ind1:1s. !or this purpose the machinability index of free cutting steel serves as a datum, with reference to which all other machinability indexes are compared. The machinability index of this steel is taken as -CC. !or computing the machinability index of any other material the following relationship is used ?

>achinability index (Y. 1`($utting speed of metal for 7C min. tool life.Q(cutting speed of standard free cutting steel for 7Cmin. tool life.aZ-CC !C#%#M(CS #, M!+A" MAC (%(%& The basic endeavour in any production process is to produce an acceptable component at the minimum possible cost. In order to achieve this ob&ective in metal cutting or metal machining, many attempts have been made in several different ways @ such as optimising the tool life in 4rder to minimise the production cost, maximising tiie production rate to reduce

the production cost, etc. Aut, no single effort has been found fully successful because of a number of complexities involved in the process. !or example, if cutting speed is reduced in order to enhance the tool life the metal removal rate is also reduced and, therefore, the production cost is increased. * similar effect is observed if effort is made to increase tool life by reducing the feed rate and depth of cut. *gainst this, if effort is made to increase the metal removal rate by substantially increasing the cutting speed, feed and depth of cut, the tool life shortens and, therefore, tooling cost increases and so the total production cost also increases. * balance is, therefore, required to be struck and a reasonable (optimum. cutting speed determined, corresponding to which an economical tool life will be ensured and an economical production will result. In order to determine the optimum cutting speed a batch of manufactured components is considered and its total cost and other cost components calculated and plotted as shown in !ig It will be observed that the tooling cost increases while the machining cost decreases with increase in cutting speed. *lso, there is a point `lowest point. /%, the total cost curve which indicates the minimum cost of production. The cutting speed (0o. corresponding to

5ffect of variations in cutting speed on various cost factors this point gives optimum cutting speed for economical production and the tool life corresponding to this optimum speed will be the most economical tool life. imilarly, the production cost per piece (Um. corresponding to this point is the minimum cost per piece. 3ow, the total production cost of a product comprises several components as follows ? -. $utting cost or machining cost. 7. Tool changing cost :. Tool grinding cost. ;. Idle cost

M#D!""(%& $10r1ssi3n Analysis? In many problems there are two or more variables that are inherently related,and it is necessary to explore the nature of this relationship.#egression analysis is a statistical technique for modeling and traversing the relationship between two or more variables. !or example,in a chemical process,suppose that the yield of the product is related to the process operating temperature.#egression *nalysis can be used to build a model at expresses yield as a function of temperature.This model can then be used to predict yield at a given temperature level.It could also be used for process optimi9ation or process control purposes. In general, suppose that there is a single dependent variable, or response y,that is related to k independent , or regressor,variables,say x-,x7,++++++++++++++++xk.The response variable is a random variable, while the regressor variables x-,x7,++++++++++++++++++ xk are measured with negligible error.The x& are called mathematical variables and are frequently controlled by experimenter. #egression analysis can also be used in situations where y,x-,x7,+++++++++++++++++xk are &ointly distributed random variables,such as when the data are collected as different measurements on a common experimental unit.The relationship between these variables is characteri9ed by a mathematical model called a regression equation. Here as per the given explanation the equation taken is 0Tn 1 $ 2here, 0 1 cutting speed T 1 tool life n 1 tool life exponent Here the set of data is taken by changing the cutting speed and the process is continued as follows? The above Taylorbs equation (-. is lineari9ed to convert the nonlinear form of equation into linear form and rewritten on a log+log scale as, "og 0 M n log T 1 log $ +++++++++++++(7. +++++++++++++++++++(-.

Therefore the Taylor,s equation represents a straight line. In order to include the effects of feed rate /f, and depth of cut /d, in the above equation, it is generali9ed and the relationship(-. is of the form, 0Tnf n-dn7 1 $.............. (:.

2here, n, n-,n7 and $- are the constants which depend on tool and work materials, tool geometry ,types of coolant used ,etc., ince Taylor,s equation does not fit the actual tool life data for many materials, with the experimental data, it is analy9ed to estimate these various parameters, for the first order model and since the first +order model determines some statistical evidence of lack of fit, a general second+order linear equation in the form of logarithmic terms has been proposed with additional data collected i.e., the parameters in the first+order are estimated using multiple regression analysis of variance performed for this model reveals some lack of fit, so that the second+order model is developed on log+log scale(:..It is expressed as, log T1 nCMn-log 0Mn7 log fMn: log d Mn-7 log 0 log fMn-: log 0 log d Mn7: log f log d where, nC, n-, n7, n:, n-7, n-:, and n7: are constants determined from the experimental data by curve fitting. for simplicity, the second order empirical model is postulated from the equation(:. as, Tp 1 nCMn-x-Mn7x7Mn:x:Mn-7x-x7 Mn-:x-x:Mn7:x7x: 2here, +++++++ (<. ++++++++ (:.

Tp+predicted value of tool life x-, x7, x: c cutting parameters The experimental deviation or residual is the difference between the predicted and observed values of tool life. $10r1ssi3n 43d1lin0 The model development is that of the dependence of the model on the data collected to constructed to construct the model, termed as '$onstruction sample(6:8.The assumption for the regression6-78 models is the estimated linear functional form, while dependence is the determination of the slope and intercept parameters using the construction data set . The empirical models are more specific than analytical models. These models are approximate only under certain conditions or for certain products. These empirical modes depend on data+its abundance, integrity, completeness and timeliness6<8.

Three levels of for each factor are selected and this paper concentrates on modeling methodology6=8 and the related model validation procedures. !or constructing the model by regression analysis, the factorial experimentation approach to design of experiments()45.6I8 is followed. The study of empirical modeling is sometimes restricted because of more number of parameters.

-J experiments

are randomly selected and conducted on the specified lathe.The

arithmetic average of surface roughness6J8 in all the experimental conditions does not exceed < microns. Aoth the #7 value the close to 9ero p value in the analysis of variance (*340*. are presented by regression analysis.

%1ural %1t93rk and ,u>>y l30i5 %1ural %1t93rk. * 3eural 3etwork is a massively parallel distributed processor made up of simple processing units, which has a natural propensity for storing experimental knowledge and making it available for use.It resembles the brain in two respects? -.Unowledge is acquired by the network from its environment to a learning process . 7.Inter neuron connection strengths,known as synaptic weights, are used to store the acquired knowledge. The procedure used to perform the learning process is called a learning algorthim,the function of which is to modify the synaptic weights of the network in an orderly fashion to attain a desired design ob&ective. A22li5ati3ns 36 %1ural %1t93rks8

teering an *utonomous 0ehicle

$all *dmission $ontrol in *T> 3etworks ,u>>y "30i58 !u99y logic refers to a logical system that generali9es classical two+valued logic for reasoning under uncertainty. It also refers to all of the theories and technologies that employ fu99y sets, which are classes with unsharp boundaries.

A22li5ati3ns 36 ,u>>y "30i5 C3ntr3l8 $onsumer products *utomotive and %ower Beneration Industrial %rocess $ontrol #obotics and >anufacturing.

The relationship between the cutting conditions and tool wear signatures can be obtained by either some mathematical interpolation techniques or neural networks. 3eural networks are comparatively useful because of non+linearity between the parameters obtained from the experiments. 3eural networks works on a logistic function which can map the inputs with outputs within the interval(C and -..* thin layer neural network consist of an input, hidden and output layer .*t the hidden and output layers the activations are completed and the outputs are evaluated. The outputs at the output layer(C. are compared with some target values(T. and the squared error is successively minimi9ed, so as to obtain a correct connection weights pattern. The following fig shows a neural network emploted in present work. !u99y logic approach is employed to predict the following levels of tool wear based on lologarithm of spindle current values as shown in table

,(%(+! !"!M!%+ A%A"'S(S? Aasically most of the turning and shaping operations are performed in orthogonal cutting manner. *t a particular tool verses work piece contact instance the resultant cutting force acting is obtained from merchantHs circle diagram. *s chip length (contact 9one. increases the stresses on the tool faces also increase. * study can be made to predict indirectly tool+wear in terms of displacements at the tool faces due to the cutting forces. !ig+: shows the finite element mesh employed with different boundary

conditions considered cutting forces.

!=P!$(M!%+A" D!+A("S A%D S!+-P

The H. . cutting tool inserts the same H. . content 6:8 are selected and the required hard turning operations are performed on eighteen engine crank pins, having same hardness values the different test conditions are shown in Table -. Test $ondition 3o 7 : ; < = I J S -C --7 -: -; -< -= -I -J peed in mQmin -CC -CC -CC -CC -<C -CC -CC -<C -<C -<C -<C 7CC -<C 7CC 7CC 7CC 7CC 7CC !eed in mmQrev C.C= C.C.C= C.C.C= C.-; C.-; C.C= C.C.-; C.C.C= C.-; C.C= C.C.C.-; C.-; )epth of $ut in mm C.: C.: C.; C.7 C.7 C.; C.7 C.: C.; C.; C.: C.: C.7 C.; C.; C.7 C.: C.7 !lank 2ear in mm C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 C.7 Tool "ife in min ;:.C ;C.C :S.< :J.< :I.C :<.C :<.C :;.< :;.C ::.C :7.< :-.C :-.C 7J.C 7I.< 7J.< 7<.< 7<.C

The required hard turning operations are performed on a lathe of -II.< mm centre height, <7C mm swing gap,-=CC rpm spee,C.C<+:.< mmQrev of feed range and main motor power of :.I U2. The geometry of selected cutting inserts is JC degrees diamond shape with a 7C degree edge shape chamter and C.-C7 mm wide;8.The outermost layer of the work piece is turned off first by using mixed alumina cutting insert in order to avoid the

hard turning of oxidi9ed layer. or the test cut ,suitable length is selected and the number of cuts vary depending upon the depth of cut. t regular intervals of time ,the tool wear and the surface roughness are measured and when the flank wear of the cutting tool comes to 7CC microns, the turning operation is stopped because ,most of the tools fracture with a flank land measurement between -JC and 7CC microns(C.-J mm and C.7 mm. 6<8. imilarly, the other turning operations with different cutting conditions are also performed with different inserts6=8.The flank wear and surface roughness values are measured at regular intervals of time until the flank wear values are tabulated in Table -,for all the eighteen test conditions .The values of speed, feed rate and depth of cut are properly utili9ed for developing the empirical tool life mode. The >icrosoft 5xcel is used in this work. * series of experiments were conducted on a conventional center lathe at various values of operating parameters. High carbon steel (J<$=. work pieces and H tool material have been chosen. Initially the grinded tool is considered to have no tool wear. The dynamometers for the force measurements have been mounted through the tool post in spindle current is measured with the help of wattmeter. The experimental setup is illustrated in the figure below.

$!S-"+S A%D D(SC-SS(#% The effect of each individual factor and factor interactions6S8 on tool life are examined with a reasonably small amount of time and cost.This research is able to include three parameters simultaneously with more accurate experimental data.The positive signs of the regression analysis mean that the tool life value goes in the same direction and negative signs mean the opposite. The magnitude of impact of each term on the tool life is studied based on the values of their coefficients. Ay using one of the optimi9ation techniques , Taguchibs design of experiments6I8, the best values of speed as -CCmQmin, feed rate as C.C= mmQrev and depth of cut as C.7 mm are identified from the data shown in the figure. 2ith these best values of parameters ,a validation experiment is conducted and the tool life is getting improved from ;: min to ;:.7< min which is better than that of any other experimental values in the table .

!rom the following table the "inear #egression for tool life is developed as, T"# 1 <=.=;S c C.--: 0+<S.IJJ f+-.SJ< d +++++++++++++++++++(=.

The percent relative deviations6-C8 between the values of tool life with various models6-C8 in all the test conditions can be calculated as,

Pr1di5t1d valu1 ? #7s1rv1d valu1 ........................................... #7s1rv1d valu1 *bsolute Y #elative )eviation 1`(;-.-I+;:.Q;:a-CC 1 ;.7=Y 2here , ;: is the experimental tool life in minutes corresponding to first test condition and ;-.-I is the predicted tool "inear #egression for Tool "ife #egression tatistics >ultiple # C.SI-<<=J # quare C.S;:S77< *d&usted # quare C.S:-SC<S tandard 5rror -.:IJ;SC= 4bservations -J *340* df > ! #egression : ;;I.ISS;IC7 -;S.7==;SC- IJ.<<-< #esidual -; 7=.=C::CI<= -.SCC7:=7<; Total -I ;I;.;C7IIIJ
Intercepts $utting peed (0. )epth of $ut (d. +--7J:CJ C.CCISJS;7J +-;.-77<CI:= -.-5+CS +C.-7SS==:S +C.CS<=S< +<.SJ=I<<SJ< :.:5+C< +J-.7CISJI= +:J.:=JS +C.;I7=7J:SI C.=;:I= +-C.SSC:=;I I.C7-7S7= +C.-7SS==; +C.CS<=S<+J-.7CISJJ +:J.:=JSC7 +-C.SSC:=< I.C7-7S7< !eed #ate (f. +<S.IJJ;;< S.SJ=IJ<C7< +-.SJ;<:=- ;.-SJS:<:;<

@ 100 ............(I.

ignificance ! <.:;::-5+CS

$oefficients tandard 5rror t tat %+value "ower S<Y Xpper S<Y "owerS<Y XpperS<Y <=.=;JI:: 7.-=I:<=C:; 7=.-:I7<7S- 7.J5+-: 7.CCC7-7:- =-.7SI7<: <7.CCC7-7 =-.7SI7<::

#esidual 4utput 4bservations %redicted F residuals 7 : ; < = ;-.-J7SS :J.IS-;<7 ;C.SJ;<:= :J.SJSSC< :<.I:SSC< :=.7C-;= -.J-IC-C:C S -.7CJ<;J-+ -.;J;<:=CJ 7 + C.;JSSC<;S J -.7=CCS;<C 7 +

#esidualsquare :.:C-<7=;=; -.;=C<JJ<:; 7.7C:JI:J; C.7;CCCI:SI -.<JIJ:J-<: -.;;:<CI7JJ

*ctual F :S.:=<SIS:J :I.<J7SC:IJ ;7.;=SCI7-= :S.;ISJ-:;.;ISJ-:I.;C7S7CS=

#> diffY

I J S -C --7 -: -; -< -= -I -J

:=.:SSS-; :<.<;-;<7 :7.S<-;= :C.<<SS7: ::.-;:SS; 7S.JSSS-; :C.S<=J: 7S.IC-;= 7I.:CSS7: 7I.IC=J: 7<.--=J:J 7<.:-<7S7

-.7C-;=C;J + -.:SSS-;CJ S +-.C;-;<-JS -.C;J<:S<S 7.;;CCII:7 + C.=;SS-;CJ S -.-CCCJ<SC.C;:-IC-C : + -.IC-;=C;J C.-SCCII:7 + -.7C=J7SJS I C.:J:-=-<7 + C.:-<7S7CS = sum average qrt of avg

-.S<SI<S;<J -.CJ;=77C:S -.CSS;:<-7: <.S<:7SII:7= C.;77:JJ:7; -.7-C-JSC-C.CC-J=:=<J 7.JS;S=II=S C.C:=-7S:JI -.;<=;:J; C.-;=J-7I;; C.CSS;CS-C= 7=.=C::=CI<= -.;IIS=-<:-.7-<I;I;;;7

:I.ISSJ7J-J :=.<J7SC:IJ < :-.SC7S7CS= 7J.--SJ;<:= ::.ISSJ7JCJ 7J.ISSJ7J-J :C.S-:=I-<S :-.;C7S7CS= 7I.--SJ;<:= 7J.S-:=<SIS 7;.I::<I=SJ 7<.=:C<J;-S sum <S=.< average ::.-:JJJJS -Vavg C.C:C-I=C7I

:=I

Table ;. "og Transformed "inear #egression for Tool "ife in minutes obtained by substituting the parameters of first test condition(Table -. in "inear regression model for tool life(eqn.=. imilarly, the absolute Y#elative )eviation can be calculated for all other models. The #> differential Y values for all the four models are calculated and shown in the corresponding #esidual out put tables.

ince the depth of cut is not having a significant individual effect6--8 on tool life, it can be increased to some extent in order to improve the material removal rate G. !rom Table, it is observed that (cutting speed E depth of cut.intersection is not more significant on tool life when compared with the other parameters and interactions. !rom Table :, the linear $ross %roduct #egression model for tool life developed as, T"$%# 1 I7.IS;+C.-=70+-IJ.Sf+:I.-;;dMC.7-I0fMC.C;-:0dM7CC.77:fdMC.=--0fd +++++++++++++(J. A7s3lut1 A$1lativ1 D1viati3n B 2.<1A

!rom Table ;,it is observed that cutting speed and feed rate are more significant on Tool life. !rom Table ;, the "og Transformed "inear #egression model for tool life is developed as, T"T"# 17.:S;+C.;JJlog0+C.-=Ilogf+C.CCJlogd *bsoluteY#elative )eviation 1 C.;;Y !rom table+<, it is observed that feed rate, (cutting speedZfeed rate.interaction and (cutting speedZdepth of cut. interaction are more significant on tool life. !rom Table+<, the "og Transformed $ross product model for tool life is developed as, T"T$%# 1 +C.I;-M-.-:Ilog0+7.I=<logf+<.-S7logdM-.:I<log0ZlogfM7.I-Jlog0Zlogd+ ;.7I;logfZlogdM7.7SIlog0ZlogfZlogd *bsoluteY #elative )eviation1C.:7Y The calculated values of absolute percent relative deviations of tool life are plotted in fig7.!rom the study of various models, it is known that all the models have a statistically satisfactory goodness of fit from the modeling point of view. The tool life values calculated with various values at all the test conditions are shown in fig: ++++++++++++++++++++++++(-C. +++++++++++++++++++++++(S.

imilarly,the "og Transformed tool life values calculated with various models at all the test conditions are shown in fig ; !rom the results of models shown in Table+=, it is observed that the "og transformed $ross %roduct #egression model shows best fit for tool life with lower values of percent relative deviation and #> Y difference even though the value of #7 is slightly lower.

*340* #egression #esidual Total df : -; -I ss C.CI=;S=:I; C.CCI;C=7J< C.CJ:SC7== > C.C7<;SJISC.CCC<7SC7 ! ;J.7 ignificance ! -.7=C;=5+CI

$oeffici ents Intercept "og $utting speed (log 0. "og !eedrate(lo gf. "og )epth of cut(log d. 7.:S:IS =J + C.;JIS< :S + C.-==<: C+ C.CCI<I C7

tandard T 5rror C.-C:;I 7;:J C.C;;-= C=C= C.C:=C< C-;J C.C;=I< =JSS

tat

%+ value -.<5+ -7 7.I5+ CJ C.CCC ; C.JI: =S

"owerS<Y Xpper S<Y 7.-I-JIC7 =I + C.<J7==S+C.7;:J< + C.-CIJ<:J : 7.=-<I7:: +C.:S:7:S

"ower S<.CY 7.-I-JIC7= I +C.<J7==S--

7:.-:; =:7C7 + --.C;S <:CC: + ;.=-S: SSSJJ + C.-=-S C;I=<

+C.CJS7C.CS7I-:<

+C.7;:J< +C.-CIJ<:J:

#5 I)X*" 4XT%XT 4bservations %redicted F 7 : ; < -.=7<:7-I -.<JJ:II7 -.=7;:I<S -.<JSI-C7 -.<;CI:C: #esiduals C.CCJ-;=I=7 C.C-:=J7IJ7 +C.C7IIIJIS+C.CC;7;S<7 C.C7I;I-;-= #esiduals square =.=:=SI5+C< C.CCC-JI7S C.CCCII-== -.JC<J;5+C< C.CCCI<;=I *ctual F -.=-I-I;S: -.<I;=S;;7 I -.=<7-<;=I I -.<S:S<SI= S -.<-:7<JJS #> diff Y

= I J S -C --7 -: -; -< -= -I -J

-.<=:CS=I -.<=;C;7< -.<:S:SI: -.<C-<CI -.;II-I7: -.<C7;<7J -.;IJ;:7S -.;IS;<--.;II;JI-.;;C<;7= -.;;7J7-< -.;-I-<:I -.;-J;J=J

+C.C-SC7J=;J +C.C-SSI;;<< +C.CC-<IJ-I: C.C7SSI-S; C.C;-:;-=I7 C.CCS;:C<II C.C-7S7JII< C.C--S-C<IS +C.C:C:7SCJ+C.CC-7CSS:; +C.C-S<I<= +C.C-C=-:<;< +C.C7C<;=I<= um *verage qrt of *verage

S C.CCC:=7CJ S C.CCC:SJSI S 7.;SC=:5+C= C.CCCJSJ:I C.CC-ICS-: ; J.JS:<J5+C< C.CCC-=I-< : C.CCC-;-J= 7 C.CCCS-SJ< : -.;=:S;5+C= C.CCC:J:7C ; C.CCC--7=; I C.CCC;77-= S C.CCI;C=7J < C.CCC;--;= C.C7C7J;;J ;

um

7 -.<J7-7<:; -.<J;C-=S< < -.<;CSI<;; 7 -.;I-<:<C: J -.;:<J:C<S = -.;S:C777C J -.;=<<C;-; ; -.;=I<;C<: < -.<CIJ-=-S 7 -.;;-I<7<= 7 -.;=7:SICI < -.;7II=I7= S -.;:SC::<7 7I.7IC<= -.:;

*verage -.<-<C:-Q*verage C.==CC<7

Table <. "og Transformed $ross %roduct #egression for Tool "ife X>>*#F 4XT%XT #egression tatistics

>ultiple # # quare *d&usted # quare tandard 5rror 4bservations

C.SI;<:7I C.S;SI-:S C.S-;<-:I C.C7C<;C< -J

*340* #egression #esidual Total df I -C -I ss C.CIS=J:<7= C.CC;7-S-:; C.CJ:SC7== > C.C--:J::=C.CCC;7-S-: ! 7=.SJC: ignificance ! -.C75+C<

$oefficients "owerS<.CY XpperS<.CY Intercept +S.-=<J:;+C.I;-:=: I.=J:-CJ7J

tandrad 5rror

t tat

%+value

"ower S<Y XpperS<Y

:.IJCS;;=J< +C.-S=CIJI<< C.J;J;J C.=<7SI;;:S C.<7J<

+S.-=<J: +7.I;7=S

I.=J:-CJ:

log(cutting -.-:=S=<-.I;-7CS-SS <.C-==7-= +7.I;7=S-; <.C-==7-=; peed. "og(feed <.<77J;:I #ate. "og(depth -7.CCIS:: 4f cut. "og(0f. <.-S-:;I+7.I=<7-I +--.C<:7IJ :.I-SI7:-:< <.<77J;:=I

+C.I;::S::;

C.;I;:<

+--.C<::

+<.-S-S=: I.I-S:SSC:I +77.:S-J<S -7.CCIS:7< -.:I<7== +7.;;CJ-< -.I-7=I=-SS <.-S-:;ICI :.<:I<;I:--C.<SSS:JS

+C.=I7<J=;I;

C.<-=;<

+77.:S-S

C.JC7SS7;:; C.I=J7=SJ<J +C.<<=CJ-;7=

C.;;C=< C.;=CCJ C.<SC:J

+7.;;CJ7 +<.-=;:= +7-.;C-J

"og(0d. 7.I-IIS-C.<SSS:S +<.-=;:<I

"og(fd. +;.7I;;S: I.=J=J--;<-7.J<7IS: +7-.;C-IIS -7.J<7IS:-

"og(0fd. 7.7S==<C; :.<7;S==-S -C.-<CI== +<.<<I;=< -C.-<CI=<S

C.=<-<:J7JI

C.<7S:S

+<.<<I;I

#5 I)X*" 4XT%XT 4bservations %redicted F - -.=7=JCI7 -.<J=<=I< : -.=CJ<I=< ; -.<SSJCI= < -.<=I=S = -.<<=;JJI I -.<=CC=7: J -.<:S7<<7 S -.<C<=SSJ -C -.;S=JJ=7 -- -.<C<J7J< -7 -.;II-:=7 -: -.;=<:J7: -; -.;<<<J7 -< -.;<;SJJ< -= -.;:S;<S: -I -.;7SICS= -J -.:S;=:77 #esiduals C.CC===-:<I C.C-<;S7<7+C.C--SIS:SS +C.C-;:;=SCJ C.CCC<--I<< +C.C-7;7CIC: +C.C-<SS;7=+C.CC-;:=-:S C.C7<IIS-C< C.C7-=7II;C.CC=C<;J<; C.C-;77<;SI C.C7<SIS;7I +C.CCJ;7:SS= +C.C-<=<<IJ; +C.C-=7-:;=+C.C7:-=S;=7 C.CC::CIJ<= um *verage qrt of *verage #esiduals square ;.;:I:I5+C< C.CCC7;CCJ C.CCC-;:<C = C.CCC7C<J: ; 7.=-JS;5+CI C.CCC-<;7I ; C.CCC7<<J= 7.C=7;S5+C= C.CCC==;<= 7 C.CCC;=II< S :.===-:5+C< C.CCC7C7:= < C.CCC=I;S: I.CS=:I5+C< C.CCC7;<-C ; C.CCC7=7JI = C.CCC<:=J7 ; -.CS;-S5+C; C.CC;7-S-: um ; C.CCC7:;:S *verage = C.C-<:-CCC -Q*verage I *ctual F -.=7C-;= -.<I-CI< -.=7C<<= -.=-;-<< -.<=I-IJ -.<=JSCS -.<I=C<I -.<;C=S-.;ISS7-.;I<7<J -.;SSII; -.;=7S--.;:S;C: -.;=;CC= -.;IC=<< -.;<<=I: -.;<7JIS -.:S-:7; 7I.7IC<= -.<-<C:C.==CC<7 -.C#> diff Y

Table = #esults of various models for the first test condition values >odels - "inear regression 7 "inear $ross %roduct #egression : "og Transformed "inear #egression ; "og Transformed $ross %roduct #egression 5xperimental %redicted Tool Tool "ife(min. "ife(min. ;: ;-.-I ;: -.=; ;-.S7 -.=: #esidual -.:C -.CJ C.C%ercent #elative )eviation ;.7= 7.<C.;; #> diff Y :.=I 7.IJ -.:; # quare C.S; C.SJ C.S-

-.=;

-.=:

C.C-

C.:7

-.C-

C.S<

$!S-"+S A%D A%A"'S(S #, ,-CC'"#& (C? 0arious experiments are carried out on turning machine with ob&ective of keeping one of the parameter constant at a time

The data is generated using :+layer perception neural network model with three inputs and four output neurons.!ig ; shows a plot of training process . >*T"*A neural network toolbox is employed to achieve an error goal of -Z-C+<.Table+: shows the simulation outputs from the neural network.

Table+; shows the fu99y logic prediction from the neural network.The material properties are given in Table+<.The !5* results are shown in Table+=,as the displacements on the flank face.The results show some intresting outcomes to predict values of damage in sample terms

Table+; shows the fu99y logic prediction from the neural network. The material properties are given in Table+<. The !5* results are shown in the Table+=, as the displacements on the flank face. The results sh39 s341 Interesting outcomes to predict levels of damage In simple t1r4s.

C#%C"-S(#%8 This paper presents the various empirical models for estimating models for estimating cutting tool life. The results obtained from various models are compared with experimental values.The values of percent relative deviation predicted by these models are then verified and it is concluded that the developed models provide a statistically satisfactory prediction. The fitness value of "og Transformed $ross %roduct #egression model for tool life is higher when compared with other models. These developed models aid to improve the tool life and for the selection of various cutting parameters.Ingeneral,it is concluded that all these empirical models developed are well suited for all the experimental conditions. 3euro+fu99y and !5* approaches have been adopted to obtain the tool wear status in turning operations. 5xperimental work has been performed to ascertain tool wear status and to arrive at input data for the 3eural 3etwork. 4rthogonal cutting model with 5lasto+ %lastic analysis is selected and plain strain elements are employed to generate the mesh for obtaining deformations on the tool flank+face. * multi parameter model involving the data containing surface roughness, actual tool wear values and accelerometer sensor output is planned as a future scope of the present work in exact measurement of the tool wear