Experimental Study on Tool Parameters of Al2O3 in High Speed Machining

Abstract

In this project work, experimentally modeling of dry high speed machining at cutting speed range of 80 to 600 m/min using Al2O3 turning insert. Studied the turning process parameters (cutting speed, feed rate and depth of cut) for machining of EN-24T alloy steel with an cutting tool Al2O3 & Carbide turning insert at cutting velocity range between 80 to 600 m/min (450 to 3000 rpm) with feed rate of 0.1 to 05mm/rev and depth of cut of 0.1 to 0.5 mm. Experiments were repeated for -6°, 0° and +6° rack angles of Al2O3 tool. Performed simulation of turning operation using Finite Elemental Method (FEM) techniques at the same cutting speed, Feed rate and depth of cut ranges for the +6° tool and cutting forces are measured from FEM analysis. Experimental Performance of Al2O3 tool was compared with Carbide tool and validated with FEA analysis. Calculated percentage of variation of cutting forces of experimental and FEA results of Al2O3 tool.