Determination and Analysis of Spindle Load in Boring Machining Operation on Cast Iron using Mathematical Models

  R.S. Kadu,  Dr.G.K. Awari,  Dr.C.N. Sakhale

Boring process in Grey Cast Iron Casting (GCIC) materials are widely used in machinery industries and particularly in automotive industries. However, improved mechanical properties of these materials limits us due to high cost of processing these materials. Spindle Load is one of the most important factors in machining operations of such materials and it is mainly affected by cutting conditions including the cutting speed, depth of cut, insert material and cooling environment along with length and diameter of the tool body. Machining manufacturing process are now moving towards automations. Therefore, Spindle Load monitoring is important to achieve an efficient manufacturing process. In this study, a tool wear prediction model during the boring machining operation of gray cast iron is studied. It is based on the monitoring of tool performance in controlled machining tests with measurements of tool life, surface finish, bore size variation, cutting time and load on spindle in terms of % current under different combinations of cutting parameters (cutting speed, depth of cut, tool nose radius, length & diameter of tool, tool material and coolant pressure & concentration). The influence of cutting parameters on the tool life was studied experimentally by performing more than 128 cutting tests. A prediction model was then developed to predict tool wear. The basic steps used in generating the model adopted in the development of the prediction model are: collection of data; analysis, pre-processing and feature extraction of the data, design of the prediction model, training of the model and finally testing the model to validate the results and its ability to predict tool wear. The evolution of boring machining operation properties using different parameters is a complex phenomenon. There are many factors (like cutting speed, depth of cut, insert material and cooling environment along with length and diameter of the tool body ) affecting the performance of cast iron boring machining operation resulting to more load on spindle. This paper presents an experimental investigations and Sequential classical experimentation technique has been used to perform experiments for various independent parameters. An attempt of mini-max principle has been made to optimize the range bound process parameters for minimizing Spindle Load during cast iron boring machining operation. The test results proved that Spindle Load was significantly influenced by changing important four dimensionless π terms. The process parameters grouped in π terms were suggested the effective guidelines to the manufacturer for minimizing Spindle Load by changing any one or all from the available process parameters.

Keywords- Gray cast iron, Spindle load, Boring machining process, Regression Analysis, RSM, Dimensional Analysis, Optimization, Buckingham‟s π terms.

Unique Identification Number - IJEDR1401181
Page Number(s) - 1002-1014
Pubished in - Volume 2 | Issue 1 | March 2014
DOI (Digital Object Identifier) -   
Publisher - IJEDR (ISSN - 2321-9939)

  R.S. Kadu,  Dr.G.K. Awari,  Dr.C.N. Sakhale,   "Determination and Analysis of Spindle Load in Boring Machining Operation on Cast Iron using Mathematical Models ", International Journal of Engineering Development and Research (IJEDR), ISSN:2321-9939, Volume.2, Issue 1, pp.1002-1014, March 2014, Available at :http://www.ijedr.org/papers/IJEDR1401181.pdf