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m
)
Tool Type
ToolWearinToolswithvaryingcuttingspeed
300rpm
400rpm
500rpm
Figure 4: Comparative Studies of the Flank Wear at Varying
Cutting Speed
3.2 Chip Morphology
The study of the chips during turning of materials play an
important role in the surface finish achieved in the machining
process. The chips produced by hard turning of hard chrome
plated surfaced were collected to study the behavior. The
nature of failure of the chip was observed under the confocal
microscope. The image of the confocal microscope is shown
in figure 5. The confocal microscope images revealed the saw
tooth type of failure of the chrome plated surfaces in the form
of chips.
Figure 5: Image of the Chip Observed Under Confocal
Microscope
To study the nature of fracture of the chip higher
magnification was required. Due to this reason these chips
were observed under SEM to study the chip morphology.
Figure 6 is the SEM image of the chip collected during hard
turning of hard chrome plated surfaces.
0
50
100
150
1 2 3 4 5 6 7 8 9
F
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a
n
k
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e
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r
(
m
Trail Numbers
200
250
)
CNGA 120404
DNGA 150404
ISSN 2277-5056 | 2012 Bonfring
Bonfring International Journal of Industrial Engineering and Management Science, Vol. 2, No. 4, December 2012 156
Figure 6: SEM Image of the Chip Produced
When observed under SEM, the chips produced showed
the nature of fracture of these from the work piece. There was
a brittle kind of fracture observed at a magnification of 500X.
The images showed that the failures of chips were brittle in
nature. These types of fractures were observed in all the
different cutting conditions. This showed that the chrome
plated surface detached from the work piece as soon as the
metal cutting started. This could be one of the reasons for
getting comparatively less temperature during finish turning of
chrome plated surfaces. The pictures clearly indicated that the
chips were saw-tooth type of chips which occurs during hard
turning. The average lengths of the chips observed were in the
range of 1mm and the average width 100 -150m. The SEM
images were shown in the figures 7 and 8.
Figure 7: The Average Width Measurement of the Chip
Figure 8: The Average Length Measurement of the Chip
The chips showed curled pattern indicating excessive
stress during removal from the uncut part. At higher
resolutions chips showed excessive cracking which clearly
indicates brittle fracture through crack propagation.
3.3 Microstructure
The micro-structural observations carried on the chrome
plated surfaces showed a good bonding between the chrome
plated surfaces and the EN24 substrate. Though at higher
magnifications there was a gap in the coating which was
observed. The further magnification images indicated that
there could be a better coating technique adapted to decrease
the gaps in the coating.
The micro structure image showed the plating and the base
material, the base material has a lot of unfilled gaps which can
be observed which will enhance corrosion, but the chrome
surface is closely packed avoiding corrosion and providing
extreme hardness on the surface to resist wear. Figure 9 shows
the SEM image at 100X magnification.
Figure 9: SEM Image of the Hard Turned Chrome Plated
Surface at 100X
When moved to higher magnifications such as 250X and
further the hard chrome coating showed the microstructures
clearly. White patches were observed when the magnification
was at 250X. Figure 10 shows the chrome plating at a
magnification of 250X.
ISSN 2277-5056 | 2012 Bonfring
157 Bonnfring Internationaal Journal of Indus strial Engineering
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Figure 10: SEM
This may be
rfaces. A deta
ture of these w
N24 base ma
agnification of
rome plating
cro-cracks by
ating paramete
e coating incre
creases the res
hese micro-crac
ereby extendin
sence of thes
ftening the coa
at the mixture o
hibit increase
sistance.
Figure 11: SEM
After detailed
chrome plated
1. The chip
plated su
M Image of the
Surface
e due to the to
ailed study on
white patches. T
aterial showed
f 10kX. Figure
on the EN24
y SEM images
ers to be contro
eases with the
sistance to corr
cks permit the
g the life of th
e micro-crack
ating. Therefor
of both micro-
ed fatigue st
M Image of the
Surface
IV. CO
d study on the
d surfaces follow
ps produced by
urfaces were in
e Hard Turned
at 250X
ool path on th
this required
The bonding of
d acceptable
e 11 shows th
substrate. Th
s at 10kX su
olled properly.
e presence of
rosion and the
lubrication to p
he coating on t
ks increases th
re the literature
-cracks and the
trength, corro
e Hard Turned
at 10kX
ONCLUSION
e tool wear du
wing conclusio
y hard turning
n the saw tooth
and Management
ISSN 2277
Science, Vol. 2, NNo. 4, December 20012
-
Chrome Plated
he chrome pla
to conclude
f the coating w
strength at
he bonding of
he appearance
uggested that
. The hardness
micro-cracks
e fatigue streng
pierce the surfa
the substrate. T
he wear rate
es have sugges
e smooth surfa
osion and w
Chrome Plated
ring hard turn
ons are drawn:
g of hard chro
h form. The ch
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hnology, Volume
urav Bartarya, S.K
ernational Journal
4, 2012.
rt Adair, Shiv G.
ology for a hard-
nufacturing Proces
A. Almeida, A.J.S
hogonal turning of
ferent angles, Vac
H. Shahabi, M.M.
ius wear from wor
chine vision, In
hnology, Volume
Kundrak, B. Karpu
ning, J of materia
, 2008.
Kang, J.S. Kim, Y
sidering the effect
SI 1045 steel, Jou
ume 225, Pp. 163-
Lalwani, N.K. M
ting parameters in
sh hard turning
hnology, Volume 2
d from the wor
the tool increas
h of cut thus re
showed a chip
and higher cu
lly was good
lower surface f
medium cuttin
ar was low at m
and medium fee
e radius directl
ered with dep
adius increase
rsa for lower to
ion of chips c
le in nature thro
mages revealed
k place durin
ed surface. Th
ess variation ob
plated surfac
ACKNOWLEDG
ortion of the
RC-0113/2009
d like to ackn
r. P.V. Shashi
I and authoriti
e funding of D
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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 2, No. 4, December 2012 158
ISSN 2277-5056 | 2012 Bonfring
ersity, Hyderabad.
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K.N. Mohandas has born at Honavar (Karnataka) on
02nd October, 1977. The author obtained his B.E.
degree in Mechanical Engineering from National
Institute of Engineering, Mysore in the year 1999 and
M.E. degree from UVCE, Bangalore in Manufacturing
Science and Engineering in the year 2003. The authors
major field of study is in the area of metal cutting. The
author is the coinvestigator of a DST sponsored R&D
project in collaboration with Central Manufacturing
Technology Institute (CMTI), Bangalore. He is pursuing his PhD degree in
JNT University, Hyderabad in the area of Hard Turning under the guidance of
Dr. C.S.Ramesh, Professor, PES Institute of Technology, Bangalore and Dr.
K. Eshwara Prasad, Professor, JNT Univ