Volume 11 Issue 4 ( December 2024)

This research article aims to explore the influences of tool rake face orientations on surface roughness, chip morphology and chip thickness ratio during dry rough turning of 16MnCr5 steel workpiece. The experiments were conducted at fixed input parameters, i.e., cutting speed (500 RPMs), feed rate (0.171 mm/rev), depth cut (0.8 mm), whereas the tool rake face orientation was varied. Further, the approach angle (90°), tool nose radius (0.8 mm) and length (200 mm) of cut were kept constant. Chip thickness ratio, surface roughness and chip morphology were considered as output responses. The experiments were conducted with an upward tool rake face orientation and a downward tool rake face orientation. While comparing the output responses of both the experiments, it was found that the surface roughness improved by 53 % with downward rake face orientation. Similarly, the chip thickness ratio was improved from 0.27 to 0.65. The crater tool wear was reduced from 0.32 mm to 0.13 mm when results of upward and downward rake face orientation are compared. Further the chip morphology transformed from blackish toothed to garish ribbon type. From the above observations, it is concluded that the performance of dry turning can considerably be enhanced by holding the tool in an orientation with a downward rake face.

Keywords: Tool rake face orientation; Surface roughness; Chip thickness ratio; Morphology of chips; 16MnCr5 steel