Performance Evaluation of Surface Integrity and Chip Morphology in Face Milling Process of Carbon Steel alloy

Abstract

With the ever-increasing quest to produce quality products at minimum cost, the use of technology in manufacturing units plays a vital role. It ascertains the reliability for a good quality product at an optimal cost with high production rates. For achieving this, industries are adapting machining at high cutting speeds with increased feed rates. However, machining at these conditions not only increases the temperature in the cutting zone that leads to faster tool wear but also results in dimensional inaccuracies leading to poor surface finish quality. The chip formation during machining is highly affected by changing input parameters, and also has an effect on the machining output parameters viz. tool wear and surface finish quality. Thus, the study of chip morphology for varied input parameters to control output responses in machining for improved machinability is proved to be significant. Overall these results need to be integrated for developing optimum cutting conditions (cutting speed, feed rate, machining environment, tool material, and geometry) for the machining process that can produce components in desired quality with minimum manufacturing cost and having a relatively high production rate. newline