Experimental Investigation Of Productivity Improvement Of Machining Process Using Multi-Tool Turning

Abstract

Machining Is A Widely Used Manufacturing Process Where Some Part Of Material Is Removed From Bulk Workpiece In The Form Of Chips. In This Thesis Work, Explores The Science Of New Techniques Of Machining Using Two Single Point Cutting Tools Simultaneously Engaged With Workpiece Material To Increase Productivity Of The Turning Process. In Order To Perform A Double Tool Turning Process, A Conventional Lathe Machine Was Modified. In Turning Process The Process Parameters Which Affect Surface Quality Of Machined Component Are Cutting Speed, Feed, And Depth Of Cut. Experimental Investigation Was Carried Out To Improve Productivity By This New Machining Technique Under The Influence Of Cutting Parameters On Cutting Temperature, Dimensional Error, Tool Wear; Material Removal Rate And Surface Roughness. The Chip Morphology And Machining Time Were Also Studied. An Analytical Analysis Was Done For Single And Double Tool Turning Process Based On Ductile Fracture Mechanics Approach And Experiments Were Also Carried Out On Mild Steel. The Analytically Predicted Cutting Temperature, Dimensional Error, Cutting Tool Wear, Surface Roughness, Material Removal Rate, Machining Time, Production Rate Were Investigated In Detail. For The Selected Cutting Parameters Of Experimental Result, It Was Observed That The Material Removal Rate Increased By 20%. A Better Machined Surface Obtained By Double Tool Turning Than Using A Single Tool Turning Method. In This Work, Cutting Parameters (Cutting Speed, Depth Of Cut And Feed) Were Optimized For Both Double And Single Tool Turning Process Using Taguchi Method. The Average Surface Roughness For Single And Double Tool Turning Were 1.76 And 1.25 Respectively. It Was Also Surprising That Material Removal Rate Increased And Machining Time Reduced By 25% In Case Of Double Tool Turning. Tool Wear Area Measured By Optical Profilometer Shows That Total Wear Zone 813.11087 Mm2 For Single Tool Turning While It Was Reduced To 45.57 Mm2 For Double Tool Turning.