Prediction of cutting forces of SPTTs produced from scrapped mating rings of face seals

Abstract

Turning operations are crucial in production processes especially for manufacturing cylindrical parts. The scrapped mating ring of face seals have been reused and studied as single point turning tool (SPTT), which has exhibited excellent turning abilities. The scrapped mating ring was strengthened. The strengthened, unstrengthened and standard tungsten carbide, were used to produce SPTTs with the following signatures: nose radius of 2mm, positive rake angles of 3^o, 5^o and 8^o respectively and used to perform turning operations on mild carbon steel (CS1030). Cutting forces and surface finish were measured using kistler type 3-component piezoelectric dynamometer and surface profilometer. The factors used for the experiment are cutting speed, depth of cut, federate, rake angle and tools. The responses were cutting force and surface finish.  With the results, predictive equations were derived for cutting forces of the three tools under consideration. The statistical analysis showed that linear cutting force, the model, depth of cut and federate are significant; whereas cutting speed, rake angle and tools are not significant at 95% confidence level. This research will provide the machine tools’ shop with tools of minimized wear, surface roughness, chatter and dimensional inaccuracies.