Introduction
In the present time most of the people are using machines for production of parts and products. This can lead to an increase in the consumption of electricity and resources. In order to improve the process of production of complex components, milling and turning operations has become an integral part in the process of machining. Therefore, the turn-based machining processes such as centerless grinding, milling, turning, and grinding are widely used by industries for complex operations or for improving accuracy and surface finish of the parts.
Turn-based machining processes such as turning and milling are energy-intensive operations and can lead to several deformations or over-heating in the parts. In order to avoid such deformations or over-heating, machine operators has to monitor their machining process frequently to detect it at an early stage. The risks of machine damage, poor product quality, and other dangerous events can be reduced with proper monitoring of the machining process. The damage and deformation caused by the over-heating of the machined parts can be avoided if the correct parameters of the machining process are applied.
The purpose of this article is to provide an overview of the causes and prevention of burning during turn-based machining processes. In the discussion, the parameters and prevention measures related to the turn-based machining during grinding and milling are discussed.
Causes Of Burning During Turn-Based Machining
Burning during turn-based machining can be caused due to multiple factors including excessive heat, unsuitable tool geometry, wrong cutting speed and feed rate, insufficient chip removal, and unbalanced cutting forces.
Excessive Heat: Excessive heat generated during turn-based machining can cause burning and melting of the workpart surface or cutting tools due to high temperatures. This can lead to a reduction in the strength, material properties, or even surface finish. In order to reduce the generation of excessive heat, using suitable coolant can be helpful.
Unsuitable Tool Geometry: Unsuitable geometry of the tool can cause higher heat generation due to poor information and increase resistance to cut. It can also lead to chipping of the cutting edge and breakage of the cutting tool. Therefore, it is important to select correct cutting tools with correct geometry to reduce chances of burning.
Wrong Cutting Speed and Feed Rate: Wrong cutting speed and feed rate can cause interrupted cutting, which can increase friction, heat, and chip load on the cutting tools. The cutting force will also increase causing wear on the cutting edges and further burning on the workpiece surface. Therefore, it is important to set appropriate cutting speed and feed rate to reduce chances of burning during turn-based machining.
Insufficient Chip Removal: Insufficient chip removal can cause increased friction and heat during machining, leading to burning or melting of the workpiece surface or cutting tools. Therefore, it is important to maintain proper cutting environment and ensure perfect chip evacuation from the machined surface.
Unbalanced Cutting Forces: Unbalanced cutting forces can cause excessive resistance to cut, leading to burning of the workpiece surface and cutting teeth. To avoid such issues, it is important to reduce the cutting forces and maintain proper cutting conditions.
Prevention Of Burning During Turn-Based Machining
Burning during turn-based machining can be avoided with proper and regular monitoring of the machining processes. Some of the preventive measures which can be adopted include:
Use of Suitable Cutting Tools: It is important to select the right cutting tools and check the geometric design of the tools regularly. The cutting tools should be designed in such a way that they can reduce friction and heat generated while machining and provide best results.
Use of Suitable Cutting Parameters and Feed Rates: The cutting parameters and feed rates should be correctly set to reduce chances of burning and extend tool life. The cutting parameters should be selected and optimized based on the material being machined and the type of machining operation.
Regular Monitoring of Machine Condition: The machine condition should be monitored properly to detect any unaccounted wear and tear. Unaccounted wear and tear can reduce the cutting ability of the machine and lead to a reduction in the surface finish of the parts.
Check the Coolant Quality: It is important to use correct quality of coolant while machining and monitor the coolant regularly to ensure it is in good condition. The coolant should be effective in dissipating the heat generated while machining and checked regularly to avoid possible burning.
Conclusion
Turn-based machining is an energy intensive process, and therefore it is important to monitor it closely to avoid burning of the parts or tools. There are several causes of burning during turn-based machining including excessive heat, unsuitable tool geometry, wrong cutting speed and feed rate, insufficient chip removal, and unbalanced cutting forces. In order to prevent burning during turn-based machining, it is important to use suitable cutting tools, appropriate cutting parameters and feed rates, monitor the machine conditions regularly, and check the quality of coolant to dissipate the generated heat.
