Experimental Investigations to Study the Effects of Microwave Treatment Strategy on Tool Performance in Turning Operatio
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Experimental Investigations to Study the Effects of Microwave Treatment Strategy on Tool Performance in Turning Operation Durwesh Jhodkar, M. Amarnath, H. Chelladurai, and J. Ramkumar (Submitted April 16, 2017; in revised form August 28, 2018; published online November 26, 2018) In the present study, microwave treatment has been used to enhance the tribological properties of singlepoint tungsten carbide (WC) cutting tool inserts such as wear resistance and hardness. The tool hardness and cutting parameters were considered to evaluate the performance of microwave-treated WC inserts in turning operation. The optimum cutting parameters were identified using response surface method (RSM)based desirability approach. The relationship between cutting parameters and output responses, viz. flank wear, cutting force and surface roughness, was developed using the RSM. The investigations revealed that the increase in tool hardness due to complex carbide formation results in a significant reduction in tool wear, cutting forces and improvement in the surface finish of workpiece. Further, the statistical models results were validated with the experimental results. Metallurgical properties of treated and untreated tool inserts were analyzed using scanning electron microscope, x-ray diffraction method and Vickers microhardness tests. The results highlighted the importance of microwave treatment in enhancing the machining performance in turning operation. Keywords
microwave treatment, optimization, post-heat treatment, RSM, tool wear
1. Introduction Nowadays, researchers are forced to pay their attention to improve the physical and mechanical properties of the existing tool materials rather than developing the new (Ref 1). Tungsten carbide (WC/Co) is a well-known cutting tool material widely used in material removal processes owing to its superior combination of high modulus, high hardness, wear resistance and moderate fracture strength (Ref 2). In recent years, microwave irradiation has emerged as an effective volumetric post-heat treatment process for cemented carbide (WC/Co) insert. The method is not only cost-effective and energyefficient but also enhances the mechanical and metallurgical properties of inserts, thereby improving the WC/Co tool life and machining performance. The microwave treatment of materials results in refinement of grain structure which liberates the residual stresses; hence, grains are adjusted, thereby causing a significant increase in the bonding strength and hardness (Ref 3-5). Cheng (Ref 6) reported that a high dielectric loss factor present in the tungsten carbide facilitates in absorption of Durwesh Jhodkar, Department of Mechanical Engineering, Indian Institute of Information and Technology, Design and Manufacturing, Jabalpur, India; and Department of Mechanical Engineering, G. H. Raisoni College of Engineering, Nagpur, Maharashtra, India; M. Amarnath and H. Chelladurai, Department of Mechanical Engineering, Indian Institute of Information and Technology, Design and Manu
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