TECHNICAL REPORT ON

RECENT STUDIES ON SURFACE FINISH AND TOOL WEAR

Submitted in partial fulfilment of the requirements for the course work of Technology of Composite Material(802) PREPARED BY By RAJSHEKHAR SHANKAR LALBONDRE [ME10F02] Research Scholar,Dept. Of Mech.Engg. ,NITK

DEPARTMENT OF MECHANICAL ENGINEERING NATIONAL INSTITUTE OF TECHNOLOGY KARNATAKA, SURATHKAL, MANGALORE -575025 FEB- 2011

Recent Studies on tool wear and surface finish Rajshekhar S Lalbondre,Research Scholar,[ME10 F02],Mechanical Department, NITK,Surathkal

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RECENT STUDIES OF TOOL WEAR AND SURFACE FINISH IN TURNING

Rajshekhar S. Lalbondre, Research Scholar, Department of Mechanical Engineering.

Abstract With the development of harder work material the tool material technology is advancing at a faster rate to enable machining of these materials at higher material removal rate with reliability of performance. Machining of hardened steels at higher cutting speeds, offers several advantages such as reduction of finishing operations, achievement of high metal removal rates and improved surface integrity. Further high speed machining provides a lot of perks like higher productivity, better surface finish and good accuracy but with the limitation of rapid tool wear rate. Tool wear and surface finish are interrelated with each other. The surface finish value is a result of tool wear. When tool wear increases, the surface finish increases. Different researchers have carried out investigations on tool wear, tool life, and surface roughness. The research work encompasses the topic of tool wear and surface finish at macro level though they are treated under separate titles. In some of the journal papers tool wear is controlled by intermittent cutting techniques and tool swinging while in others good surface finish is obtained with round nosed tools. Surface Integrity studies and investigations of AISI 1045 and Inconel 718 work material is made considering various machining parameters using specific tools. Co-related studies of tool wear and surface finish are made in continuous and interrupted hard turning. Influence of cutting fluids on tool wear and surface roughness of stainless is also made. This report presents an overview of the recent research on tool wear and surface finish studies. The report tries to highlight the salient features of each of them. Keywords: Tool wear, Surface integrity, Surface finish, Surface roughness

1 Introduction The report deals with the studies of two major aspects of turned materials. The studies related to tool wear and the studies related with surface finish. Studies on tool wear include tool wear control in diamond turning by using ultra-intermittent cutting method and tool swinging techniques. The effect of tool wear on surface finish for a case of continuous and interrupted hard turning is dealt in this report. The influence of cutting fluids (vegetable oil) on the tool wear during turning on specific material is also included in the report. The experimental study with the round nosed tool on the surface finish; the effect of machining parameters and cutting tool geometry on surface integrity; investigations on surface integrity; experimental investigations with regards to dry machining; and surface
Recent Studies on tool wear and surface finish Rajshekhar S Lalbondre,Research Scholar,[ME10 F02],Mechanical Department, NITK,Surathkal

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modifications in tribological contacts is highlighted in this report. Excessive tool wear is a major drawback to the ultra precision cutting of steel with geometrically defined singlecrystal diamond tools. The paper [2] presents a new approach to reduce this wear. In general, the wear of the diamond tool is due to chemical reactions such as diffusion into the steel, oxidation, graphitization, and carbide formation under cutting conditions of high temperature and high pressure. To suppress these types of chemical reactions, the contact time between the diamond tool and the steel in the cutting process was controlled by intermittent cutting method such as fly-cutting or milling. A series of intermittent cutting experiments were carried out to control the toolwork piece contact time in one cutting cycle by changing the cutting speed and cutting length in each cutting cycle. The experimental results showed that the diamond tool wear was highly dependent on the tool work piece contact time, regardless of the cutting speed, and that the wear was greatly reduced by decreasing the contact time to less than 0.3ms under these cutting conditions. It is expected that steel can be successfully cut with a single-crystal diamond tool by controlling the toolwork piece contact. 2) Diamond tool wear in intermittent cutting. 2.1 Introduction .The wear of diamond tools in the cutting of steel is not due to mechanical abrasion by the friction between the diamond tool and the steel workpiece. Rather, the wear is caused by chemical reactions such as diffusion into the steel workpiece, oxidation, graphitization, and carbide-formation under high-temperature and high-pressure cutting conditions. Diamond diffusion is the main reason why the diamond tool wears down. Therefore, the amount of tool wear depends on the cutting temperature and the duration of the contact between the diamond tool and the steel workpiece. Fig. 1 shows the temperature profile of the tool edge for intermittent and continuous cutting. In continuous cutting, the cutting temperature rises rapidly at the start of the cut and quickly reaches a steady-state temperature that is too high for cutting steel, so excessive diamond tool wear occurs. In the case of intermittent cutting, the cutting temperature is changed cyclically with the real-cut and air-cut phases, and the temperature of the tool is moderated by cooling during the air-cut time when there is no contact between the tool and the workpiece. If the contact time between the tool and the workpiece is significantly reduced in each cycle, then the tool is away from the workpiece before the continuous-cutting steady-state temperature is reached. This means that the chemical reaction between the diamond and the steel is also reduced

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During intermittent cutting, the toolworkpiece contact time in one cutting cycle is determined by dividing the cutting length in one cutting cycle by the cutting speed. The toolworkpiece contact time is reduced either by reducing the cutting length in one cycle or by increasing the cutting speed. An increase in cutting speed means an increase in the working quantity per unit time, which causes the cutting temperature to rise and thus accelerates tool wear. The factors related to increasing the tool edge temperature and accelerating the wear are the cutting volume in one cutting cycle, the cooling conditions, and the tool edge shape parameters such as the rake angle and the clearance angle. 2.2 Experimental method and conditions This paper reports the results of an experimental investigation of the effect s on diamond tool wear of the cutting speed and the toolworkpiece contact time in one cutting cycle. Fig. 2shows the experimental set up in which the stainless-steel workpiece was fixed to the face plate of a rotating spindle and cut with a single- crystal diamond cutting tool. The machine used for the cutting experiments was a five-axis ultra precision machine (ULC-100C (H3); ToshibaMachine Co.,Tokyo,Japan). The work spindle of the machine was used with a high-performance electric motor and a high-precision aerostatic bearing with a run-out accuracy of about 5 nm. The guide way used was a highly rigid VV roller bearing with non-circular system and slight undulation was kept under 20 nm. The positioning accuracy of axes was kept at about 5 nm using a 1nm scale feedback To control the toolworkpiece contact time (cutting time) in one rotation of the workpiece, a narrow convexity was formed on edge was worn out and rounded after cutting 100mm. the work surface prior to the start of the experiment. Thus, one rotation of the workpiece represents one cycle of intermittent cutting, and the convexity width determines the cutting length in one cutting cycle. The rotational speed of the work spindle was controlled as a function of the distance of the cutting point from the center of the work spindle to maintain a constant cutting speed
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2.3 Conclusion. In this study, an ultra-intermittent cutting method was used to suppress the wear of diamond tools when cutting steel and a mechanism for suppressing the tool wear was described. The toolworkpiece contact time in one cutting cycle and the cutting speed were identified as the parameters that influence the tool wear, and then an experimental analysis was conducted using intermittent cutting of stainless steel with a single-crystal diamond tool for different combinations of these parameters. The wear of the diamond tool was highly dependent on the toolworkpiece contact time regardless of the cutting speed, and the wear was significantly reduced by sufficiently decreasing the contact time in one cutting cycle. It is expected that steel can be successfully cut with a single-crystal diamond tool by controlling the contact time with ultra-intermittent cutting 3) Tool swinging in cutting method 3.1 Introduction. A tool-swinging method was proposed to reduce tool wear in diamond turning of high-strength mold materials [11]. A round-nosed diamond tool was swung by rotating the B-axis rotary table of the machine, the center of which was aligned with the tool center. The tool-decentering error was detected and compensated for by an on-machine measurement system. The effects of tool-swinging direction, swinging speed, lubricant type, and tool rake angle were investigated. The tool wear was greatly reduced compared to the conventional method. A surface finish of 4 nm Ra was obtained on reaction-bonded silicon carbide by generating continuous 3.2 Experimental procedures An ultra precision lathe, NACHI-ASP15, was used in the experiments. Fig. 4 shows a schematic of the lathe. The lathe has an air-bearing spindle, two perpendicular linear tables (X- and Z-axes), and a rotary table (B-axis). The linear tables are supported by hydrostatic bearings and are driven by servomotors via hydrostatic screws. Laser hologram scales are used to position all of the tables, enabling a positioning resolution of 1 nmper step. The rotary table is also supported by high-stiffness hydrostatic bearings, and is driven by a friction drive in order to prevent backlash movements. These characteristics of the rotary table guarantee a high-accuracy tool-swinging movement. A three dimensionally adjustable tool post was developed and placed on the B-axis rotary table. A threecomponent piezoelectric dynamometer, Kistler 9256C2, was embedded into the tool post to measure the cutting forces. A CCD microscope system was fixed above the diamond tool to observe and assist positioning of the tool. An on-machine profiling system, which has a repetitive measurement accuracy of 20 nm, was attached to the X-slide table in order to measure the cross-sectional profile of the machined surface. Before cutting SiC, a copper workpiece was pre-cut using the tool-swinging method. The tool-decentering error, namely, the error between the tool curvature center and the B-axis center, is detected from the cross-sectional profile of copper workpiece by the on-machine measurement system. The error data is then fed back to the numerical control program. In this way, the form error of the workpiece can be controlled in the sub-mm level. The workpiece was reactionbonded SiC having a diameter of 30 mm and a thickness of 10 mm. The elastic modulus, bending strength and hardness of the workpiece material are 407 GPa, 780 MPa, and 26.3
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GPa, respectively. In the experiments, round nosed cutting tools made of single-crystal diamond were used. All of the tools have the same nose radius (10 mm) and crystalline orientation. Three different rake angles, namely, 08, _208, and _408, were used to examine the rake angle effect. The spindle rotation speed was set to 1000 rpm, the tool feed rate and the depth of cut were set to 20 mm/min and 2 mm, respectively. The tool-swinging speed was set to five levels, namely, 58/min, 158/min, 308/min, 458/min, and 608/min by controlling the rotation speed of the B-axis table. As lubricants, kerosene mist and grease having a high MoS2 micro-particle content were used, respectively.The grease was applied as a thin film on the workpiece surface.

As shown in Fig. 3, a swinging movement is applied to a round nosed diamond tool in diamond turning. The center of curvature of the cutting tool is adjusted to be in agreement with the center of rotation of the B-axis rotary table of the machine. By swinging the rotary table, the cutting point will constantly vary with respect to the tool edge during machining. As a result, the cutting time for a certain cutting point becomes very short and the temperature increase at this point will be dramatically reduced. In addition, the tool can be well lubricated as it swings, because lubricants can easily penetrate the tool-workpiece interface. In metal cutting, the cutting fluid enters the cutting zone as a result of the kinetic action of the capillary network in tool-chip interface and
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forms a boundary lubrication layer by physical and chemical adsorption onto the capillary wall . However, when cutting high-strength ceramic materials, the tool-workpiece contact pressure is extremely high, so that the capillary network is hard to form, and the fluid cannot enter the cutting region. This situation, however, can be improved by rotary cutting. 3.3 Conclusion The lubricant around the tool can penetrate both the rake face side and the flanks face side as a result of the tool-swinging movement and enhance the lubrication effects. Based on the two aforementioned aspects, we expect that the tool-swinging cutting method will greatly improve the tool life in machining high-strength mold chip materials. A tool-swinging cutting method was proposed and verified by ultra precision diamond turning tests on reaction-bonded SiC. Due to the tool-swinging movement, tool wear was significantly suppressed, and the roughness of the machined surface was reduced. The use of a highly negative rake angle tool and swinging the tool in the forward direction at high speed (>308/min) are recommended. Grease containing MoS2 micro-particles provided better lubrication than kerosene mist. In the test cuts, a surface finish of 4 nm Ra was obtained by generating continuous chips. 4)Tool wear effect on surface finish for continuous and intermittent hard turning 4.1 Introduction Steel components are often hardened for reasons of wear resistance and production technology. Due to component quality requirements (surface finish, accuracy of shape and size), the parts must be finished in a highly heat-treated or hardened state. The machining of hardened steel components with PCBN inserts having a geometrically defined cutting edge has gained substantially in importance due to improvements in the performance of such modern cutting tool materials. However, there are still insufficiently explored areas related to tool wear and surface quality that make implementation of this technology slow. This[7] paper presents aspects related to surface quality for a case of interrupted and continuous hard turning. New findings concerning the evolution of common surface roughness parameters as well as the evolution of surface topography with the increase of tool wear are presented. The study employs two workpiece materials that were less considered for hard turning investigations to the authors best knowledge. A good correlation between flank wear aspect and machined surface was observed. A different surface finish evolution was remarked for the continuous and interrupted cutting situations. 4.2 Experimental details 4.21 Work pieces Two types of workpieces were considered for continuous and interrupted cuts respectively. The continuous surface belonged to a camshaft and was 155mm long with 28.6mm diameter. The material was 1117 steel hardened up to 621 HRC. The 1117 steel is usually used where a combination of good machinability and more uniform response to heat treatment is needed. The amount of manganese allows for better hardenability when comparing to other steels from the same group (i.e. 1109, 1114, 1115), permitting oil quenching after case hardening heat treatments in many instances. The chemical
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composition is presented as follows: 0.140.20% C, 1.001.30% Mn, 0.040% P (Max.) and 0.080.13% S(Max.). The workpieces having longitudinal interruptions were shafts having 10 splines. The surface to be machined was 63.8mm long and had 34.9mm diameter. The spline-shafts were made of 1137 steel having a medium hardness of 481 HRC. This type of steel is widely used for parts where a large amount of machining is necessary, or where threads, Splines or other operations offer special tooling problems. The main elements of the chemical composition have the following percentages: 0.320.39% C, 1.351.65% Mn, 0.040% P (Max.) and 0.080.13% S (Max) 4.22 Cutting tools The tools available for this research were specifically designed for hard turning applications and their main characteristics are presented next. Amborite DBC50 is a low content, fine grain PCBN material on a tungsten carbide base. The CBN content is 50% by volume in a TiC binder phase, and the average CBN grain size is 2_m. Amborite DBN45 is a low content PCBN material (45%CBN) with a sub-micron grain size (0.51 _m) integrally bonded with a titanium nitride (TiN) ceramic binder onto a tungsten carbide base. The cutting inserts were of TNMA432T type and the tool holder was MTJNLS-164D type. Thus, the main cutting angles after the PCBN inserts were clamped in the toolholder were: rake angle 25, relief angle 5 and side cutting edge angle 3. The cutting edge had the same preparation consisting in a chamfer at 20 over 0.15mm and an edge hone of 0.025mm radius. The tool nose radius was 0.8 mm. 4.3 Conclusion The paper presents the results of an experimental study focused on the influence of tool wear on surface finish in interrupted and continuous OD hard turning. A combination of workpiece materials and tools not yet considered for hard turning investigations was adopted for this research. Four types of wear trials were initially completed to determine the behavior and wear mechanism of the cutting tools employed. The major wear mechanism was found to be the abrasion of the binder material by the hard particles of the workpiece. In the case of continuous hard turning the notch groove has a rapid increase to a steep shape while the cutting edge does not display significant irregularities. In the case of spline shaft turning, the notch groove has a wider aspect and the cutting edge displays chipping due to shocks. The tool material had more influence on tool lifespan rather than its wear mechanism. The analysis of surface topography confirmed that the negative of the flank wear profile is replicated on the machined surface. A strong correlation between evolution of notch wear and that of surface finish was observed. In the case of continuous cutting, the Ra, Rz and Rpk tend to increase significantly with tool wear, while in the case of interrupted cutting the opposite effect is recorded. In interrupted cutting a special care should be given to burr formation, which can damage the adjacent surfaces. 5) Surface modifications in tribological contacts 5.1 Introduction
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A characteristic of almost any type of dry or boundary lubricated tribological contact is that the composition and tribological properties of the original interface will change during use. The modifications include topography changes (smoothening or roughing), formation of micro-cracks, phase transformations, deformation hardening, formation of oxides, formation of solid films by reactions with lubricant additives, transfer of material from the counter surface, and so on. The thickness of these layers and films range from atomic monolayers (e.g., hydrogen termination of diamond surfaces) to tens form (e.g., plastic deformation of metals). Since the tribological properties of tools, wear parts and mechanical components then are determined by these modified surfaces rather than by the original, they deserve attention and careful assessment. Without the knowledge about how these surface layers are formed and how they modify the tribo system, it is not possible to predict the friction and wear properties of amaterial in a given tribological situation. Thus, post-test evaluation including microscopy and analysis of both surfaces and cross-sections is required.A number of surface modifications selected from a wide variety of tribosystems is briefly presented [3]. The corresponding surface modifications range from the best known and simple to the more complex and relatively unexplored. Finally, the potential of designing materials and lubricants for improved surface modification is discussed and examples are given of current research projects on promoting formation of protecting low-friction tribo films in boundary-lubricated systems In practice, several of these categories often combine, sometimes in rather complex ways. This multitude of possible mechanism and combinations of mechanisms calls for great caution whenever analysing the materials used or tested in tribological applications. This paper sets out to demonstrate the decisive importance of surface modifications and tribo film formation in tribology, by presenting a selection of examples spanning a wide range of mechanisms from the four categories. A better understanding of these phenomena will aid in analysing the friction and wear in technical applications and can potentially be exploited by intentionally designing surfaces and lubricants that generate beneficial tribo films and surface modifications. Although outside the scope of the present paper, also topographical alterations may significantly modify the tribological performance, and should also be considered.

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Fig. 6. The four basic categories of tribological surface modification: (a) modification without any material transfer; (b) modification involving material transfer; (c) formation of tribofilm or coating; (d) wear (loss of particles or atoms from the surface) 5.2 Discussions. During operation, almost any tribological surface becomes modified with respect to composition, structure, hardness and other properties relevant to the tribological action. Very often the new surface materials exhibit totally different friction and wear properties compared to the original bulk materials [1,2]; the friction may be reduced or increased, the wear resistance may be better or worse. Four main categories of surface modifications can be distinguished (see Fig. 6): (a) modification of the original surface without any material transfer (mechanisms include deformation hardening, fatigue, crack generation, local changes of composition and phase due to diffusion, etc.); (b) modification of the original surface involving material transfer (mechanisms include diffusion and possibly chemical reactions with atoms ormolecules originating fromthe mating surface or surrounding media. Tribo-oxidation of metals is a very important example in this category.);

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(c) formation of tribofilm or coating on top of the original surface (atomic or particle scale formation, possible mechanisms include transfer from the mating surface, pick-up and compaction of loose particles, adsorption of additives from the lubricant, etc.); (d) wear (loss of particles or atoms from the surface). In practice, several of these categories often combine, sometimes in rather complex ways. This multitude of possible mechanism and combinations of mechanisms calls for great caution whenever analysing the materials used or tested in tribological applications. In practice, several of these categories often combine, sometimes in rather complex ways. This multitude of possible mechanism and combinations of mechanisms calls for great caution whenever analysing the materials used or tested in tribological applications. This paper sets out to demonstrate the decisive importance of surface modifications and tribofilm formation in tribology, by presenting a selection of examples spanning a wide range of mechanisms from the four categories. A better understanding of these phenomena will aid in analysing the friction and wear in technical applications and can potentially be exploited by intentionally designing surfaces and lubricants that generate beneficial tribofilms and surface modifications. Although outside the scope of the present paper, also topographical alterations may significantly modify the tribological performance, and should also be considered. 5.3 Conclusion As elucidated by the few examples collected in this paper[3], tribofilms and modified surfaces have a decisive effect on the tribological performance of very different types of mechanical components and tools. Of course the list of examples could be made much longer, but the key message would remain the same. Include the tribofilms and surface modifications in all analyses of tribological components or tribological tests. Their importance is often highly underestimated, which repeatedly have lead researchers, mechanical designers and material developers to draw the wrong conclusions. The full appreciation of their decisive roles in the performance of the tribological interface will enable design of materials, coatings, lubricant additives and surface topographies with potential to meet the steeply increasing requirements of performance in combination with a sustainable society. 6) Surface integrity enhancement investigation studies using burnishing tools 6.1 Introduction Low plasticity burnishing (LPB) is relatively a new method of surface enhancement, which raises the burnishing to the next level of sophistication. LPB can provide deep stable surface compression for improved surface integrity characteristics. The present study[4] focuses on the surface roughness, microhardness, surface integrity and fatigue life aspects of AISI 1045 work material, using full factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in terms of evaluating the interaction effects of parameters, identifying the predominant factor amongst the selected parameters, their order of significance and setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness and fatigue life. Mathematical expressions were developed for surface characteristics of importance as
Recent Studies on tool wear and surface finish Rajshekhar S Lalbondre,Research Scholar,[ME10 F02],Mechanical Department, NITK,Surathkal

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response variables. Subsurface microhardness studies were also done to assess the depth of compression, altered material zone and correlate fatigue life with surface roughness and surface hardness. The process can be applied to critical components effectively, as the LPB ocess today has significant process cycle time advantages, and lower capital cost. Additional cost reduction will be realized by introducing proven high speed machining concepts into the LPB process.

6.2 Experimental work Surface integrity and enhancement of any material is governed by several factors and their interactions. It is necessary to know quantitatively about the influence of these factors and their interactions on the response variables. In this context, it is desirable to have mathematical models of the process, which will help in the selection of suitable values of process parameters for getting the best possible outcome, in terms of reduced surface roughness and enhanced surface hardness and fatigue strength. The quantitative analysis of surface integrity has also found to be quite complicated as there are many process parameters. Hence, the database for surface finish, surface microhardness and fatigue are usually generated on the basis of extensive experimentation and practices. Furthermore, mathematical models of the process can also be obtained through such experimentation. 6.3. Work material The experiment work was carried out to investigate the effect of some of the process parameters of LPB on surface roughness, surface hardness, fatigue life and surface
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integrity characteristics of AISI 1045 work material, which is a most commonly used metal in varieties of general applications ranging from small scale to mass production hi-tech. industries. Typical applications include spindles of machine tools, gears, nuts and bolts, and shafts in marine and automotive engineering. Focus of this research work is to identify the potentiality of the technology, demonstrate and transfer this novel technology to remote rural industry/s, which needs to be nurtured and protected against cutthroat global competition. 6.4 Specimen preparation Cylindrical workpiece materials were prepared as per the ASTM requirements to conduct fatigue tests. Using the general conditions of turning, the medium quality surface Roughness texture was achieved, which are evident in common manufacturing practices. Initial surface roughness was 4 mm (Ra) and surface hardness was found to be 187 Hv. The surface roughness (Ra, Arithmetic average) of an unburnished and low plasticity burnished specimen was measured by Talysurf (SE model-1100) at each specified region, with cut off values taken as 0.8 mm. An average of five measurements was taken for each replication. The surface hardness was measured using microhardness tester MVH-1 with a test load of 0.98 N. Fatigue tests were conducted on workpieces prepared using a standard R.R. Moore type rotating type of fatigue machine. A standard specimen, which was turned using general conditions of machining and prior to LPB, was tested for fatigue life, that was used as reference value with respect which the fatigue life increase caused by LPB of workpieces were observed and evaluated. The speeds of rotation of the specimen were 4340 rpm and the bending moment applied was 19.62Nm. The fatigue life evaluated for unburnished specimen was initially found to be 238,798 cycles. 6.5. Experimental procedure Design of experiments was done using full factorial [2k] design methodology, with randomization and replication of experiments, without blocking, since one factor at a time approach would not have given the clear picture of interaction effects between the parameters [21,22]. The LPB process parameters considered for studies were: burnishing pressure, burnishing speed, diameter of ball,number of passes and other parameters were held constant, as their effect was not highly significant as seen from the preliminary studies [20]. In the present study, the focus was on the surface roughness, microhardness, fatigue life and surface integrity aspects. 6.6 Conclusions Favorable and optimum conditions could be predicted for different requirements of finish, hardness and economy of process. Database developed from the experimental analysis could be very useful for the selection of best possible process parameters and conditions for finishing various machine components, economically. Surface roughness up to 0.53 mm, surface hardness up to 421 Hv and fatigue life up to 1,701,280 cycles could be achieved by this process, which can be applied to critical components effectively, as the LPB process today has significant process cycle time advantages. LPB technology
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enhances not only the surface finish, hardness of the surface and fatigue strength, but also, many surface properties such as corrosion resistance, out of roundness, wear resistance, etc. The parameters that have greater influence on the surface roughness and fatigue life response variables in the decreasing order of importance are pressure, speed, ball diameter and number of passes whereas speed, pressure, ball diameter and number of passes is the order for surface hardness response variable. No single factor has the dominant effect on the surface roughness as all the parameters are interacting and have combined effect, whereas speed is the single dominant factor affecting surface hardness and pressure is the one dominant factor affecting fatigue life. To minimize the roughness of the surface, it is advisable to set the speed, pressure, number of passes at high level and ball diameter at low level. However, to maximize the surface hardness it is advisable to set all the parameters to low level and to maximize the fatigue life, setting all the parameters to high level is found to be beneficial. In the present study, the depth of compression was found to be more than 1.1 mm, which is a significant achievement of LPB process, being an affordable, effective means of surface enhancement that can provide deep, stable surface compression for improved surface integrity. 7) Overall Conclusion Tool wear in diamond is suppressed by an ultra-intermittent cutting method than continuous cutting by reducing the tool- workpiece contact time. In tool swinging movement,the tool wear was significantly suppressed, and the roughness of the machined surface was reduced. In case of continuous cutting the roughness value tend to increase significantly with tool wear, while in the case of interrupted cutting the opposite effect is recorded .However,in interrupted cutting a special care need to be given to burr formation. During turning of AISI 304 austenitic stainless steel, coconut oil was found to be a better cutting fluid than the conventional mineral oils in reducing the tool wear and surface roughness. As feed is reduced in turning or facing with round nosed cemented carbide inserts, the insert feature that controls surface roughness changes from nose radius to edge sharpness. Tribofilms and modified surfaces have a decisive effect on the tribological performance of very different types of mechanical components and tools. The full appreciation of their decisive roles in the performance of the tribological interface will enable design of materials, coatings, lubricant additives and surface topographies with potential to meet the steeply increasing requirements of performance in combination with a sustainable society. Low Plastic Burnishing is an affordable and effective means of surface enhancement that can provide deep, stable surface compression for improved surface integrity.

8) References
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[1] Salak.A, Vasilko.K and Selecka.M. (2006), New short time face turning method for testing the machinability of PM steels., Journal of Material Processing Technology, 176 , pp 62 69. [2]YoungChan Song, Kentaro Nezu, Chun-Hong Park and Toshimichi.(2009), Tool Wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method., International Journal of Machine Tools and Manufacture ,49, pp 399 343. [3] Staffan Jacobson and Sture Hogmark.(2009), Surface modifications in tribological contacts. ,Wear ,266, pp 370 378. [4] Seemikeri.C.Y, Brahmankar. P.K and Mahagaonkar.S.B. (2008), Investigations on surface integrity of AISI 1045 using LPB tool. Tribology International,41 , pp 724 734. [5] Pawade.R.S, Joshi Suhas and Brahmankar. P.K.(2008), Effect of machining parameters and cutting edge geometry on surface integrity of high speed turned Inconel 718. International Journal of Machine Tools and Manufacture ,48, pp 15 28.
[6] Prasad .M.V.R.D, Ranga Janardhana G and Hanumantharao.D.(2009), Experimental investigation to study the influence of process parameters in dry machining. ARPN Journal of Engineering and Applied Sciences ,pp 91 94 [7] Radu Pavel, Marinescu Ioan,Mick Dies and Jim Pillar.(2005), Effect of tool wear on surface finish for a case of continuous and interrupted hard turning. Journal of Material Processing Technology, 170, pp 241 349 [8] Pawade.R.S, Joshi Suhas, Brahmankar P.K and Rahman,M.(2007), An investigation of cutting forces and surface damage in high-speed turning of Inconel 718. Journal of Material Processing Technology, 192 , pp 139 146 [9] Xavior Anthony and Adithan M. (2009), Determining the influence of cutting fluid on tool wear and surface roughness during turning of AISI 304 austenitic stainless steel. Journal of Material Processing Technology,209, pp 900 909 [10] Umbrello.D, Outerio.J.C and MSaoubi.R.(2010), A numerical model incorporating the microstructure alteration for predicting residual stresses in hard machining of a AISI 52100 steel. CIRP Annals- Manufacturing Technology,59, 113 - 116 [11] Yan.J, Zhang.Z and Kuriyagawa.T(2010), Tool wear control in diamond turning of high strength mold materials by means of tool swinging. CIRP Annals Manufacturing Technology, 59 , pp 109-112 [12] Childs.T.H.C, Sekia.K, Tezuka.R and Yamane.Y(2008) , Surface finishes from turning and facing with round nosed tools CIRP Annals-Manufacturing Technology, 57, pp 89 92

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