LITERATURE REVIEW
Turning generates cylindrical and rounded forms with a single point tool. The turning definition is
that the tool is stationary with the workpiece rotating.
A turning operation is the most common process for metal cutting and is a highly optimized process,
requiring thorough consideration of the various factors in the turning application.
Turning can be broken down into a number of basic applications (longitudinal turning, facing and
profiling), requiring specific types of tools, cutting data and programming for the operation to be
performed in the most efficient way.
INITIAL CONSIDERATIONS FOR TURNING -
Consider the following dimensions and quality demands of the component to be machined:
● Type of applications, for example, longitudinal or profiling, internal or external
● Type of methods, for example, roughing or finishing
● Large, stable component
● Small, long, slender, thin-walled component
● Corner radius
● Quality demands (tolerance, surface finish etc.)
After considering the features, look at the component:
● Does the material have good chip-breaking qualities?
● Is chip evacuation a critical issue? Mass production justifies an optimized Tailor Made tool
to maximize productivity
● Batch size, a single component or mass production?
● Can the component be fixed securely?
Machine considerations include:
● Stability, power and torque, especially for larger components
● Coolant supply or dry machining
● Is high pressure coolant for chip breaking in long-chipping materials necessary?
● Tool changing times/number of tools in turret
● Limitations in rpm, especially for bar feed magazine
● Sub-spindle, or tail stock available?
RECENT DEVELOPMENTS IN METALWORKING INDUSTRY AND
TURNING TOOLS -
[Link] to Reduce cycle times and produce more parts in turning processes
[Link] reduction in turning processes
3.3D printing in manufacturing
Innovation to Reduce cycle times and produce more parts in turning processes -
● Sandvik Coromant’s innovative Prime Turning tools can rough and finish parts in
simultaneous passes allowing production levels to increase.
● The PrimeTurning methodology enables you to do turning in all directions in a much
more efficient and productive way compared to conventional turning.
● This latest innovation let users cut not just in a forward motion, but also in reverse and
away from the chuck. You can go in one direction and perform high-feed roughing and
you can actually come back with the front of the tool and traditionally turn to finish the
part.
● PrimeTurning is more useful to shops in the aerospace and automotive industries, though
it is applicable, in any shop where large-batch productions require external turning
operations.
Vibration reduction in turning processes -
● Silent Tool Plus enables data from the machining process to be collected and sent to a
dashboard, giving the operator a valuable insight into what is happening inside slender
tubular components.
● The Silent Tools Plus vibration indicator is able to detect issues with machining at an
early stage, helping to prevent vibration-associated issues such as noise, poor surface
quality and accelerated tool wear.
● The range of Silent Tools from Sandvik Coromant is designed to minimize vibration
through a pre-tuned damper inside the tool body that consists of a heavy mass supported
by rubber spring elements.
● The benefits of this design are multi-faceted, allowing machine shops to increase metal
removal rates, improve surface finish, secure the process or reduce production costs.
3D printing in manufacturing –
● The 3D printed carrier or tool holder is often better than the steel one. When the parts are
being machined, developing complex carrier designs become impractical.
● Creating tooling to hold the inserts at precise orientations requires five-axis machining
and/or additional setups in order to machine the needed angles into the carrier.
● 3D printing is unaffected by complexity—it simply prints a tangible model of whatever
CAD geometry is provided. 3D printing has the main advantage to have a very short lead
time production. Manufacturing a tool in a few days or even a few hours is made very
simple.
● 3D printing also reduces cost as there are no costs related to machine setup and finishing
as in traditional manufacturing and allows to improve and optimize the existing tools
with new features.
HEAT GENERATION ON CUTTING TOOLS -
● During machining heat is generated at the cutting point. The heat generated is shared by
the chip, cutting tool and the blank.
● The effect of the cutting temperature, particularly when it is high, is mostly detrimental to
both the tool and the job. The major portion of the heat is taken away by the chips. But it
does not matter because chips are thrown out.
● So, attempts should be made such that the chips takeaway more and more heat leaving a
small amount of heat to harm the tool and the job.
● The possible detrimental effects of the high cutting tool temperature on cutting (edge)
are:-
[Link] tool wear, which reduces tool life
[Link] deformation of the cutting edge if the tool material is not enough hot-hard and
hot-strong
[Link] flaking and fracturing of the cutting edges due to thermal shocks
[Link]-up-edge formation
● The possible detrimental effects of cutting temperature on the machined job are:
[Link] inaccuracy of the job due to thermal distortion and expansion-contraction
during and after machining
[Link] damage by oxidation, rapid corrosion, burning etc.
The magnitude of cutting temperature is more or less governed or influenced by all the
machining parameters like :
● It is already seen that high cutting temperature is mostly detrimental in several respects.
Therefore, it is necessary to control or reduce the cutting temperature as far as possible.
Cutting temperature can be controlled in varying extent by the following general
methods:
i. proper selection of material and geometry of the cutting tool(s)
[Link] selection of VC – so combination without sacrificing MRR
[Link] selection and application of cutting fluid application of special technique, if
required and feasible.
