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The document outlines a research project focused on the experimental investigation of hot machining for high-strength materials, addressing challenges in conventional machining such as tool wear and surface quality. It aims to evaluate the effects of hot machining on tool wear, cutting forces, and surface quality, while identifying optimal preheating temperatures and cutting parameters. The study seeks to contribute to sustainable machining practices that enhance productivity and align with environmental standards in industries like aerospace and automotive.

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2 views

rp endsem file

The document outlines a research project focused on the experimental investigation of hot machining for high-strength materials, addressing challenges in conventional machining such as tool wear and surface quality. It aims to evaluate the effects of hot machining on tool wear, cutting forces, and surface quality, while identifying optimal preheating temperatures and cutting parameters. The study seeks to contribute to sustainable machining practices that enhance productivity and align with environmental standards in industries like aerospace and automotive.

Uploaded by

yash gupta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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ENDSEM EVALUATION

RESEARCH PROJECT 2024-25

PROJECT NAME:
EXPERIMENTAL INVESTIGATION OF HOT-
MACHINING OF HIGH STRENGTH
MATERIAL.
ROLL NO.: 121ME0463
NAME: YASH GUPTA
SUPERVISOR
SHRI KALIPDA MAITY
TABLE OF CONTENTS
1.INTRODUCTION AND MOTIVATION
2.LITERATURE REVIEW
3.RESEARCH GAP
4.OBJECTIVES OF PROJECT WORK
5.METHODOLOGY
6.RESULTS AND DISCUSSIONS
7.SCHEDULE OF FUTURE WORK TO
BE DONE
8.REFERENCES
Introduction
High-strength materials such as titanium alloys, nickel-based
superalloys, and advanced high-strength steels (AHSS) have
become increasingly vital in industries like aerospace,
automotive, biomedical, and power generation. Their superior
mechanical properties, such as high strength-to-weight ratio,
corrosion resistance, and thermal stability, enable the production
of components with long-lasting performance in extreme
conditions. However, machining these materials presents
significant challenges due to their hardness, toughness, and
thermal conductivity, which contribute to rapid tool wear, high
cutting forces, and poor surface quality. Conventional machining
methods, even with advanced tool materials and coatings, often
fail to address these challenges economically and efficiently. As a
result, there is a pressing need to explore innovative machining
methods, such as hot machining, that can overcome these
difficulties.
Hot machining, a technique that involves preheating the
workpiece to reduce its hardness and improve machinability, has
shown potential in addressing these challenges. By heating the
material prior to or during the machining process, hot machining
reduces the cutting forces and energy requirements, facilitating a
more efficient material removal process. In addition, preheating
can enhance tool life and improve surface finish, two critical
parameters for high-performance parts. This experimental
investigation focuses on exploring the effectiveness of hot
machining in enhancing machinability and achieving desired
quality in high-strength materials.
Motivation
The motivation for this study stems from the limitations of
conventional machining practices when applied to high-strength
materials and the growing industrial demand for components
made from these materials. Traditional machining of high-
strength alloys results in rapid tool wear, high energy
consumption, and compromised surface quality, often making the
process cost-prohibitive and environmentally unsustainable. High
tool costs, frequent tool changes, and poor surface quality result
in increased downtime and production costs, which can reduce
the competitiveness of manufacturers that rely on these
materials. Additionally, challenges in machining high-strength
materials often necessitate specialized tool coatings and
advanced cooling systems, further increasing the complexity and
cost of the process.
Hot machining has emerged as a potential solution to address
these machining difficulties. Preheating the workpiece prior to
machining reduces its hardness, thereby lowering the cutting
forces, minimizing tool wear, and facilitating a more stable
machining process. Studies indicate that hot machining can help
in achieving lower energy consumption and longer tool life,
making it a promising technique to enhance productivity and
sustainability. The investigation aims to contribute valuable
insights into optimal preheating temperatures, cutting
parameters, and tool materials for specific high-strength alloys,
paving the way for more effective industrial application of hot
machining techniques.
In addition to economic considerations, there is a need to meet
strict quality standards and sustainability goals. The aerospace
and automotive industries, in particular, are driven by rigorous
safety, performance, and environmental standards that demand
precision machining with minimal environmental impact. By
investigating the feasibility and optimization of hot machining for
high-strength materials, this study seeks to contribute towards
the development of sustainable machining practices that not only
improve productivity but also align with environmental
regulations.
Objectives
This study will experimentally investigate the following:
1. Evaluate the effects of hot machining on tool wear, cutting
force, and surface quality in high-strength materials.
2. Identify optimal preheating temperatures for specific high-
strength materials to achieve reduced hardness and
improved machinability.
3. Assess the influence of different cutting parameters on hot
machining performance, including cutting speed, feed rate,
and depth of cut.
4. Compare the effectiveness of different tool materials and
coatings when used in conjunction with hot machining.
5. Determine the economic and environmental benefits of hot
machining in comparison to conventional machining
methods.
The insights gained from this study will contribute to the broader
understanding of hot machining’s potential to revolutionize the
machining of high-strength materials, providing a basis for
further research and practical implementation. The findings could
lead to more efficient, cost-effective, and environmentally
sustainable manufacturing processes, benefitting industries that
rely on high-strength materials for high-performance
applications.
LITERATURE REVIEW
1. Numerical simulation of effects of machining
parameters and tool geometry using DEFORM-3D:
Optimization and experimental validation
YEAR 2014
AUTHOR T. Tamizharasan N. Senthilkumar
MAJOR  Optimization of machining
FINDING parameters and tool geometry in turning AISI 1045
steel using carbide cutting inserts.
 Cutting insert shape was identified as the most
significant factor, contributing 37.84% to quality
characteristics, followed by cutting speed (13.47%)
and depth of cut (11.56%).
 The optimal conditions reduced wear depth,
interface temperature, and cutting force by
18.81%.
METHODOLO Finite Element Analysis (FEA) using DEFORM-3D
GY software for simulation.
Experimental validation was conducted to verify
simulation results.

2. Numerical analysis and experimental


investigation in the machining of AISI 316 steel
YEAR 2020
AUTHOR A.K. Parida, P.V. Rao, and S. Ghosh
MAJOR  The study investigated the
FINDING effects of cutting speed and feed rate on the
machining performance of AISI 316 steel.
 It found that higher cutting speeds reduce
cutting forces due to thermal softening, while chip
morphology changes from continuous to segmented
with increased cutting speed.
 Simulation results showed a 10% error compared
to experimental findings, affirming simulation
accuracy.
METHODOLO  Finite Element Modeling
GY (FEM) with DEFORM-2D was used for simulating the
cutting process.
 Experiments were conducted to validate
simulated results, focusing on cutting forces,
temperature, and chip morphology at different
speeds and feed rates.
3. Hot Machining of High Manganese Steel: A Review
YEAR 2008
AUTHOR Orhan Çakır and Erhan Altan
MAJOR  Hot machining, which involves heating the
FINDING workpiece before or during machining, improves
the machinability of high manganese steel.
 Benefits observed include longer tool life,
reduced cutting forces, better surface finish, and
higher material removal rates compared to
conventional machining.
METHODOLO  Review of hot machining applications for high
GY manganese steel.
 Comparative analysis of machining parameters
like cutting speed, feed rate, and depth of cut in
hot versus conventional machining.
 Examination of various heating methods,
including electric current, flame, induction, and
plasma arc, and their impact on machinability.
4.
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
5.
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
6.
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
7.
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
8.
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
9.
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
10. Machinability of High Mn Steel Using Tool Life
Criteria
YEAR
AUTHOR
MAJOR
FINDING
METHODOLO
GY
REFERENCES
1. Metal Cutting: Theory And Practice by
Bhattacharya.
2. https://www.researchgate.net/publication/
261269588_Numerical_Simulation_of_effects_of_Mac
hining_parameters_and_Tool_Geometry_using_DEFO
RM-3D_Optimization_and_Experimental_Validation
3. https://link.springer.com/article/10.1007/s12046-
019-1235-5
4. https://www.researchgate.net/publication/
261269588_Numerical_Simulation_of_effects_of_Mac
hining_parameters_and_Tool_Geometry_using_DEFO
RM-3D_Optimization_and_Experimental_Validation
5. https://ouci.dntb.gov.ua/en/works/lDegwRL9/
6. https://www.researchgate.net/publication/
343049191_The_Effectiveness_of_Hot_machining_pr
ocess_for_the_Machinability_of_Hard_to_cut_materia
ls_A_REVIEW
7. https://www.sciencedirect.com/science/article/pii/
S0263224118309709
8. https://www.researchgate.net/publication/
252415499_An_Experimental_Investigation_of_Hot_
Machining_with_Induction_to_Improve_Ti5553_Machi
nability
9. https://link.springer.com/article/10.1007/s12046-
019-1127-8
10. https://www.sciencedirect.com/science/article/
pii/0020735771900461
11. https://link.springer.com/article/10.1007/
s40962-023-01044-3
REFERENCES

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