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STUDY OF THE BEHAVIOR OF VARIOUS MILD STEEL GRADES DURING THE MACHINING PROCESS USING A CNC TURNING MACHINE

 

Introduction

Mild steel grades, such as EN8 and EN24, are widely used in industries like automotive, aerospace, and construction due to their excellent machinability, weldability, and affordability. To meet the increasing demand for high-precision and high-quality mild steel components, it is essential to understand their machining behaviour. This project aims to investigate the machining behaviour of EN8 and EN24 mild steel grades during the turning process using a CNC turning machine, evaluating the effects of cutting speed, feed rate, and depth of cut on cutting forces, surface roughness, and tool wear.

 

How CNC Machines Works

CNC (Computer Numerical Control) machines are automated machining tools controlled by a computer that executes pre-programmed sequences of machine control commands. They are used in manufacturing to produce precise and complex parts with high accuracy and efficiency.

 

1)   Design & Programming – A CAD (Computer-Aided Design) model is designed and translated into a CAM (Computer-Aided Manufacturing) file.

 

2)  G-Code Generation – The CAM software compiles into G-code, a programming language that directs the motion of the machine.

 

3)     Machine Execution – The CNC machine interprets the G-code and moves in accordance with the programmed instructions to produce the desired shape or part.

 

Types of CNC Machines

CNC (Computer Numerical Control) machines are computer-programmed, automated machining devices. Following are the primary categories of CNC machines

A.  CNC Milling Machine – Employing rotating cutting tools to remove materials.

B.   CNC Lathe – Spins the workpiece while cutting tools form it.

C.   CNC Router – Suitable for cutting plastic, wood, and soft metals.

D.  CNC Plasma Cutter – Employing a high-temperature plasma torch to cut through metals.

E.   CNC Laser Cutter – Utilizes a laser beam to cut accurately.

F.   CNC Electrical Discharge Machine – Employs electrical sparks to form materials.

Materials Used

EN8 Steel: EN8 is a medium-carbon steel containing about 0.40% carbon. It is extensively used in cases where there is moderate tensile strength and excellent machinability.

EN24 Steel: EN24 is a steel alloy with high carbon, containing approximately 0.40% to 0.50% of carbon. It contains alloying elements of chromium, molybdenum, and nickel, which impart superior mechanical properties to EN8, including greater tensile strength, hardness, and resistance to fatigue.

Cutting Tool

The cutting tool employed in this project is a 0.8 mm nose radius tungsten carbide insert with a clearance angle of 7°. The cutting tool is held on a tool holder and fixed on the CNC turning machine.

CNC Turning Machine Setup

CNC turning is done on a Computer Numerical Control (CNC) lathe machine. The lathe can control cutting parameters like spindle speed, feed rate, and toolpath direction.

1.       Tool Material: Carbide inserts are utilized because they have high wear resistance and can accommodate the high temperatures that are developed during machining.

 

2.       Cutting Fluids: A coolant (typically an oil-based emulsion) is employed to minimize friction and heat generation during cutting.

Experimental Procedure

1.      Choosing the machining parameters, including cutting speed, feed rate, and depth of cut.

      2.      Workpiece preparation by machining it to the required length and diameter.

      3.      Mounting the cutting tool on the tool holder and fixing it to the CNC turning machine.

      4.      Securing the workpiece on the CNC turning machine by a chuck or collet.

      5.      Plugging the sensors and measuring devices into the CNC turning machine and workpiece.

      6.      Mounting the temperature sensor on the workpiece and cutting tool.

      7.      Conducting the experiment with the chosen machining parameters.

8.       Measuring the response variables, including cutting forces, surface roughness, and wear on tools.

Result

The findings of the research show that the machining characteristics of EN8 and EN24 mild steel grades are greatly influenced by the machining parameters. The best machining parameters for EN8 mild steel grade were determined to be a cutting speed of 150m/min, feed rate of 0.2 mm/rev, and depth of cut of 1.5 mm. Similarly, the best machining parameters for EN24 mild steel grade were established as a cutting speed of 120 m/min, feed rate of 0.15 mm/rev, and depth of cut of 1.2 mm.

Conclusion

Finally, in this study, the machining behavior of EN8 and EN24 mild steel grades has been examined during turning using a CNC turning machine. The findings have demonstrated that the machining characteristics of the steel grades are influenced to a large extent by the machining parameters. The optimum machining parameters for the different steel grades have been determined, and the findings can be utilized for optimizing the machining process for increased productivity and quality of the product. The research has added knowledge on the machining characteristics of the mild steel grades and has presented useful information for industry practitioners.

Author Bios:

1. S. Mohankumar, - AP/Mech,

2. S. Sanjai,   – IV Mech

3. S. Srirooban, – IV Mech

4. B. Vihash, – IV Mech

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