Dimensional analysis and ANN simulation of chip-tool interface temperature during turning SS304

OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. No. 4 2021 cutting tool material, its geometry, and cutting conditions play an important role while machining these steels. The researchers observed higher chip-tool interface temperature with uncoated tools followed by TiC / TiN and TiC / Al 2 O 3 / TiN coated carbide tools. The interface temperature was observed increasing rapidly with the increase in the feed and cutting speed. However, the increase in the cutting temperature accelerated the tool wear and signi fi cantly affected the tool life [1-2]. Pal et al. [3] developed mathematical model to predict the chip-tool interface temperature. Their study showed that the cutting speed and cutting depth were more signi fi cant for increasing the temperature of the interface. Abhang et al. [4] developed the thermoelectric relationship between the cutting tool and the work material. Their study showed that the cutting speed followed by feed had a prominent effect on cutting temperature during turning of EN-31 steel. Alvelid [5] used the tool-work thermocouple principle. The author carried out the calibration by using the direct heating of the calibration material with the help of an electric current through a resistance element or induction coil which was placed against the contact point of the two materials. His study showed that the thermo-electric potential was signi fi cantly affected with the heating and cooling rates. Chinchanikar and Choudhury [6] also developed a mathematical model to predict the average chip-tool interface temperature based on experimental observations. Their study correlated the EMF (electromotive force) and the interface temperature based on the tool-work thermocouple principle. Their study showed that the cutting speed with subsequent feed has a signi fi cant impact on the interface temperature, and the cutting depth has a negligible effect on the interface temperature. In another study [7], they found higher interface temperature for harder working material than softer working material. Panneerselvam et al. [8] investigated the chip-tool interface temperature for the powder metallurgy-made cutting tools. Their study revealed that cutting speed has a signi fi cant impact on the interface temperature. Bapat et al. [9] developed a numerical model to obtain temperature distribution in hard turning of AISI 52100 steel. The temperature distribution model as a function of heat generation was developed using explicit ABAQUS and the approach of an Arbitrary Lagrangian-Eulerian formulation (ALE). Their study showed that cutting temperature increases with the increase in cutting speed. The simulated results of the temperature distribution showed a good agreement with the results available in the literature. Dhar et al. [10] reported rapid deterioration in the surface roughness due to the increase in cutting temperature and stress at the tool tip. The tool-work thermocouple principle was used to measure the chip- tool interface temperature. Anagonye et al. [11] performed the calibration of the tool and work materials with the oxy-acetylene torch that was used as a heating source for the tool-work thermocouple technique. Their study showed decrease in the cutting temperature with the increase in the included angle and nose radius of the insert due to availability of more area for conduction of heat. It follows from the analyzed literature that the cutting parameters, especially the cutting speed and feed, signi fi cantly affect the temperature of the chip-tool interface. Most of the studies attempted measurement of cutting temperature during machining using the tool-work thermocouple method. However, there is very little research on the cutting temperature, considering the in fl uence of cutting parameters and the type of tool coating when turning SS304 . Moreover, very few attempts are found on modeling cutting temperature using dimensional analysis and arti fi cial neural networks. Considering the above facts, the present work investigates the chip-tool interface temperature during turning SS304 with uncoated and PVD single-layer TiAlN and multi-layer TiN / TiAlN coated carbide tools. In addition, for a better understanding of the process, an attempt was made to develop a model for predicting the temperature of the chip-tool interface using size analysis and ANN simulation. Experimental Details In the present work, the chip-tool interface temperature was investigated during turning of SS304 stainless steel workpiece having the diameter and length of 90 mm and 300 mm, respectively, using uncoated and PVD single-layer TiAlN and multi-layer TiN / TiAlN coated carbide tools. The ISO speci fi cations of the uncoated insert and tool holder used in the present study are given in Table 1. The nose radius of the