ENGINEERING RESEARCH INSTITUTE THE UNIVERSITY OF MICHIGAN ANN ARBOR A MACHINABILITY EVALUATION OF GROUPS XII-XVI OILS ON THE MULTIPLE-SPINDLE AUTOMATIC SCREW MACHINE 0. w. Boston R. E. lcKee Department of Production Engineering Project 2080 SINCLAIR RESEARCH LABORATORIES, INC. HARVEY, ILLINOIS January 1956

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ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN CONCLUSIONS 1. The levels of 175 microinches for turning and 200 microinches for forming appear to be satisfactory in adjudging the tool life (number of pieces per tool grind) when evaluating cutting fluids on the multiple-spindle, automatic screw machine. In some cases, however, visual inspection of the samples was used to supplement the graphical data, as was explained in the "Test Results." 2. In the machining of various steels on a multiple-spindle, automatic screw machine, the 4316 oil shows better characteristics ifi heat transfer, and the resulting improvement in tool life (indicated by surface roughness as acriteribn), than do the other oils, with oils L589 and 4332 running a close second in all-around performance. 3. Feeds of 0.0031 inch/revolution for turning and 0.001 inch/ revolution for forming seem to give reasonable tool life on the various steels that are included in this study. The feed of 0.004 inch/revolution which was used on the second forming operation was definitely too heavy and resulted in short tool life in all cases. A cutting speed of 117.5 feet per minute is reasonable on the AISI 1141 and 4145 materials, but should be reduced for production on the 8620 steel to insure. larger number of parts per tool grind. ii

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN AN EVALUATION OF OILS NO. L581, L589, 4332, AND 4316 AS APPLIED TO THE OPERATION OF A NEW BRITAIN-GRIDLEY, 6-SPINDLE, AUTOMATIC SCREW MACHINE IN THE MACHINING OF AISI 1141, 4145, AND 8620 STEELS Operating Conditions Machine A New Britain-Gridley Model 60, 6-spindle, automatic screw machine was used in the testing of three steels and four oils for this series of tests. Oils Oils No. L581, L589, 4332, and 4316 as received from the company were used in the above machine. Test samples of each of the first two oils were sent to the laboratory for verification of condition. Steels The certification of analysis of each material from the supplier and the Brinell Hardness Number (BHN) are listed as follows: BHN 3000-kg Steel C Mn P S Si Cr Mo Ni load 1141.41 1.37.025.090.10 223 4145.44 1.04.021.021.28 1.05.13 223 8620.21.86.019.023.31.49.17.50 217 The 4145 and 8620 steels were prepared in an annealed and cold-drawn condition and the 1141 in a cold-finished state. All materials were 13/16 inch outside diameter and from 10 to 12 feet in length.

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN Cutting Tools Turning. —The turning tools were M-3-D High-Speed Steel (Universal Cyclops) of 6% Mo, 4% Cr, 2.4% V, and 6% W. The tools were ground to the following signatures: Oil 1st turn 2nd turn L581 17,2,8,8,6,0,1/64 17,2,8,8,6,0,1/64 L589 17,2,8,8,6,0,1/64 17,2,8,8,6,0.1/64 4332 17,2,8,8,6,0,1/64 8, 15,8,8,6,0,1/64 4316 17,2,8,8,6,0,1/64 8,15,8,8, 6,0,1/64 The signature was held constant on the first turning tool for all tests. However, the tool signature was varied on the second turning tool to observe any improvement in number of pieces produced before failure of the tool. Forming. -The form tools were purchased as 18-4-1 High-Speed Steel (18% W, 4% Cr, 1% V). The following back-rake angles were ground on the tools: Oil 1st form 2nd form L581 150 80 L589 15~ 0~ 4332 150 150 4316 15~ 15~ The back-rake angle on the first forming tool was held constant for all tests while the back rake on the second-form tool was varied to observe any improvement in number of pieces produced before failure of the tool and to determine if the feed rate of 0.004 inch per revolution was a deterrent to good performance. Test Method The AISI 1141 steel was machined under the first machine setup at 117.5 feet per minutes (556 rpm) and feeds of 0.0031 inch/revolution on the turning tools, 0.001 inch/revolution on the first form, and 0.004 inch/ revolution on the second form, using the L589 oil. All machine spindles were checked for accuracy and variations in surface finish on the machined parts..e.

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN The No. 2 spindle was chosen as representative of the average of all six, and the work pieces that were retained for subsequent examination and surface-roughness inspections were taken from this same spindle at intervals of approximately thirty pieces throughout the life of the test. The three steels and four oils were tested under the above conditions. Test Criteria It was determined that values of surface roughness (microinches, rms) would be obtained from the first and second turn and the first- and second-form surfaces by averaging the values of three readings on each surface as measured by a micrometrical profilometer. These values were plotted as ordinate vs number of pieces as abscissa for each of the roughness inspections throughout the life of the test. The drills that were used in producing 5/16-inch-diameter holes did not show consistent evidence of tool wear and thus were not included in the evaluation of the test data. In running tests on oils 4332 and 4316, the drilling operation was eliminated altogether. Test Results After all data had been plotted, it was observed that a value of 175 microinches, rms, was representative of average tool life for the turning tools and 200 microinches, rms, for the form tools. These values are shown on each of the Figs. 1 through 28 to indicate the number of pieces produced prior to tool failure (inability to produce desirable surface finish). Figs. 1-6 show the results obtained in testing the L581 and L589 oils in turning 1141, 4145, and 8620 steel. Solid lines were used to show the trend of the first-turning operation while dashed or broken lines were used for the second turn. Figs. 7-12 show the results obtained in testing the L581 and L589 oils in forming 1141, 4145, and 8620 steel. Solid lines were used to show the trend of the first-forming operation while dashed or broken lines were used for the second form. Figs. 13-16 show the results obtained in testing the 4332 and 4316 oils in turning 1141 and 4145 steel. Solid lines were used to show the trend of

ENGINEERING RESEARCH INSTITUTE ~* UNIVERSITY OF MICHIGAN the first-turning operation while dashed or broken lines were used for the second turn. In most cases, two sets of turning tools failed prior to the failure of one set of form tools. Figs. 17-20 show the results obtained in testing the 4332 and 4316 oils in forming 1141 and 4145 steel. Solid lines were again used to show the trend of the first-forming operation while dashed or broken lines were used for the second form. Figs. 21-24 show the results obtained in any one turning operation, using one steel, for the four different oils, i.e., Fig. 22,first-turning operation on 4145 steel, using oils L581, L589, 4332, and 4316. Figs. 25-28 show the results obtained in any one forming operation, using one steel, for the four different types of oil, i.e., Fig. 26, firstforming operation on 4145 steel, using oils L581, L589, 4332, and 4316. The following is a quick reference chart to assist in finding the graph for any one operation with any combination of oil and steel. The numbers on the chart represent the corresponding figure numbers on the graphs. GRAPH REFERENCE CHART Oil Steel L581 L589 4332 4316 1141 -- 2,21 13,21 14,21 1st 4145 3,22 4,22 15,22 16,22 turn 8620 -- 6 -- 1141 1,23 2,23 13,23 14,23 2nd 4145 3,24 4,24 15,24 16,24 turn 8620 6 1st 1141 7,25 8,25 17,25 18,25 form 4145 9,26 10,26 19,26 20,26 8620 11 12 -- 1141 7,27 8,27 17,27 18,27 2nd 4145 9,28 10,28 19,28 20,28 8620 11 12. -- The following Table I shows the values of the number of pieces obtained prior to tool failure as defined by 175 microinches for turning and 200 microinches for forming. These values were found in the majority of cases by direct interpolation from the various graphs, in some cases, visual inspection superseded the graphical data. This was due to the

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN tendency of the built-up edge on the tool to produce a rough surface (profilometer readings above the average in microinches, rms) for a few samples and then a return to normal after the built-up edge had changed. On the other hand, a tool which had failed sometimes showed a tendency to produce a burnished or torn surface, resulting in a good profilometer reading (below the average in microinches, rms), but an unsatisfactory finish as shown by visual inspection. Therefore, direct interpolation alone, in some cases, does not give clear and accurate results. In Table I the machining of AISI 1141 steel with the 4316 oil shows the most improvement in the number of pieces produced before tool failure in both the turning and forming operations. The 4332 and L589 oils show very little difference in the turning operation, but the forming cuts favor the 4332 oil over the L589 and indicate a similarity in performance with the 4316 oil. The worst performance is shown by the L581 oil in both the turning and forming operations. In the machining of AISI 4145 steel, oils L581 and L589 show the best performance of the four in the turning operation, with slight differences in the number of pieces produced before tool failure. Oil L589, however, is definitely superior to the others in the forming operation. Oil 4316 rates second to the L589 in the forming operation, and oils L581 and 4332 third and fourth, respectively. In the machining of AISI 8620 steel, oil L589 shows ability to aid in producing more pieces per tool grind than the L581 oil in each of the cases shown. This steel was not tested with the 4332 and 4316 oils at the request of Mr. Ford Teeter. TABLE I NUMBER OF PIECES OBTAINED PRIOR TO LOSS IN SURFACE FINISH lst Turn 2nd Turn 1st Form 2nd Form Steel Oil 0.0031 feed 0.001 feed 0.004 feed 175 microinches 200 microinches 1141 L581 * 180 800+ 88 1141 L589 555 335 900+ 245 1141 4332 520 420 1080 525 1141 4316 660 660 1400+ 750 4145 L581 4o5 485 440 80 4145 L589 380 135 850+ 115 (Tool Failure) 4145 4332 190 230 230 75 4145 4316 220 220 525 65 8620 L581 * 125 O0* 0* 8620 L589 180 190+ 65 * *No test results. **Roughness over 200 microinches, rms, at start.

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