Mathematical Apparatus for Predicting Cutting Tool Life in Turning Process After Prior Plastic Deformation

2019 ◽  
pp. 1107-1114
Author(s):  
D. Kraynev ◽  
A. Bondarev ◽  
Z. Tikhonova
Keyword(s):  
Plastic Deformation ◽  
Tool Life ◽  
Cutting Tool ◽  
Mathematical Apparatus ◽  
Turning Process ◽  
Prior Plastic Deformation

Experimental Tool Wear Observation of Assisted High Pressure Cryogenic Jet in Hard Turning Process

2017 ◽  
Author(s):  
Dong Min Kim ◽  
Do Young Kim ◽  
In Su Jo ◽  
Tae Jin Song ◽  
Kyung Soo Paik ◽  
...  
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Tool Life ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Alumina Ceramic ◽  
Cryogenic Cooling ◽  
Turning Process ◽  
Dry Conditions

The hard turning process is widely used in automobile and heavy machinery industries. Extreme cutting conditions like high temperature and tool wear rate, are associated with the hard turning process. Cubic boron nitride (CBN) cutting tool is generally preferred for hard machining operations. However, higher tool cost, and tool failure due to thermal shock limits its widespread usage. In machining performance analysis, tool wear is an important parameter which is directly related to the cost of the machining process. Previous studies have reported the improvement in tool life by using cryogenic coolant as a cutting fluid. Objective of this paper is to investigate the effect of cryogenic cooling on the tool wear of CBN and Ti-coated alumina ceramic cutting tools used in the hard turning of AISI 52100 hardened steel. High pressure cryogenic jet (HPCJ) module was optimized and configured to use it for hard turning case. Computational fluid dynamics (CFD) based simulation was used to test and optimize the nozzle design for the flow of cryogenic coolant. It was validated by fundamental heat removal test. Ceramic and CBN cutting tools were then used for hard turning of parts using HPCJ module. Flank wear lengths for various cooling conditions were measured and analyzed. It was observed that the higher tool life of a Ti-coated alumina ceramic can be achieved under cryogenic cooling technique, as compared to the CBN insert under dry conditions. Cost analysis of these hard turning cases was also conducted to check the feasibility of its usage under realistic shop floor conditions. It was observed that the machining using Ti-coated ceramic under cryogenic jet may reduce the total tooling cost compared to CBN cutting tool conducted under dry conditions.

Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

2019 ◽  
Vol 947 ◽  
pp. 160-166
Author(s):  
Nutrada Khumjeen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Turning Process ◽  
Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

scholarly journals Application of Cr,Mo-(Cr,Mo,Zr,Nb)N-(Cr,Mo,Zr,Nb,Al)N multilayered composite multicomponent coating to increase the cutting tool life in turning steel

Procedia CIRP ◽  
2021 ◽  
Vol 101 ◽  
pp. 274-277
Author(s):  
Alexey Vereschaka ◽  
Marina Volosova ◽  
Nikolay Sitnikov ◽  
Filipp Milovich ◽  
Nikolay Andreev ◽  
...  
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Multilayered Composite ◽  
Multicomponent Coating

Comparative Analysis between Conventional and Dry Turning

2017 ◽  
Vol 261 ◽  
pp. 267-274
Author(s):  
Pantelis N. Botsaris ◽  
Chaido Kyritsi ◽  
Dimitris Iliadis
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Cutting Tool ◽  
Spindle Motor ◽  
Air Cooling ◽  
Machining Parameters ◽  
Turning Process ◽  
Dry Cutting ◽  
Cold Air ◽  
Cooling And Lubrication

In this paper, there is an attempt to monitor and evaluate machining parameters when turning 34CrNiMo6 material under different cooling and lubrication conditions. The machining parameters concerned are temperature of the cutting tool and the workpiece, level of vibrations of the cutting tool, surface roughness of the workpiece, noise levels of the turning process and current drawn by the main spindle motor. Four different experimental machining scenarios were completed, specifically: conventional wet turning process, dry cutting and two additional modes employing cooling by cold air. Experimental data were acquired and recorded by an optimally designed network of sensors. Experimental data were statistically analyzed in order to reach conclusions. According to the research that has been done, although, overall, minimum cutting tool and workpiece temperatures were observed under wet machining, cold air cooling is capable of achieving comparable cooling results to wet machining. The lowest values of surface roughness were achieved by wet machining, whereas the lowest level of cutting tool vibrations were observed under cold air cooling.

A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2007 ◽  
Vol 7 (3) ◽  
pp. 192-202 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Critical Component ◽  
Turning Process ◽  
Boolean Operations ◽  
Feature Based ◽  
Solid Modeler ◽  
Turning System

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

Model for Optimization of the Tool Life and the Cutting Speed for Maximum Productivity at Drilling of the Steel 2NiCr185

2015 ◽  
Vol 760 ◽  
pp. 433-438 ◽  
Author(s):  
Ovidiu Blăjină ◽  
Aurelian Vlase ◽  
Marius Iacob
Keyword(s):  
Mathematical Model ◽  
Stainless Steel ◽  
Tool Life ◽  
Stainless Steels ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Research Directions ◽  
Maximum Productivity ◽  
Optimum Cutting ◽  
New Research

The research in the last decade regarding their cutting machinability have highlighted the insufficiency of the data for establishing of the optimum cutting processing conditions and the optimum cutting regime. The purpose of this paper is the optimization of the tool life and the cutting speed at the drilling of the stainless steels in terms of the maximum productivity. A nonlinear programming mathematical model to maximize the productivity at the drilling of a stainless steel is developed in this paper. The optimum cutting tool life and the associated cutting tool speed are obtained by solving the proposed mathematical model. The use of this productivity model allows greater accuracy in the prediction of the productivity for the drilling of a certain stainless steel and getting the optimum tool life and the optimum cutting speed for the maximum productivity. The obtained results can be used in production activity, in order to increase the productivity of the stainless steels machining. Finally the paper suggests new research directions for the specialists interested in this field.

Current Progresses of Laser Assisted Machining of Aerospace Materials for Enhancing Tool Life

2013 ◽  
Vol 690-693 ◽  
pp. 3359-3364
Author(s):  
Shou Jin Sun ◽  
Milan Brandt ◽  
John P.T. Mo
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
State Of The Art ◽  
Aerospace Industry ◽  
Cutting Temperature ◽  
Machining Process ◽  
Metallic Materials ◽  
Aerospace Materials ◽  
Beam Position ◽  
Laser Assisted Machining

A higher strength and heat resistance are increasingly demanded from the advanced engineering materials with high temperature applications in the aerospace industry. These properties make machining these materials very difficult because of the high cutting forces, cutting temperature and short tool life present. Laser assisted machining uses a laser beam to heat and soften the workpiece locally in front of the cutting tool. The temperature rise at the shear zone reduces the yield strength and work hardening of the workpiece, which make the plastic deformation of the hard-to-machine materials easier during machining. The state-of-the-art, benefits and challenges in laser assisted machining of metallic materials are summarized in this paper, and the improvement of tool life is discussed in relation to laser power, beam position and machining process parameters.

Optimum Tool Life and Cutting Speed for the Maximum Productivity at the Drilling of the Steel X6CrNiTi18-10

2013 ◽  
Vol 837 ◽  
pp. 28-32
Author(s):  
Ovidiu Blăjină ◽  
Aurelian Vlase ◽  
Vlad Darie
Keyword(s):  
Stainless Steel ◽  
Tool Life ◽  
Stainless Steels ◽  
Cutting Tool ◽  
Programming Model ◽  
Cutting Speed ◽  
Maximum Productivity ◽  
Optimum Cutting ◽  
Nonlinear Programming Model ◽  
New Research

The research in the last decade regarding their cutting machinability have highlighted the insufficiency of the data for establishing of the optimum cutting processing conditions and the optimum cutting regime. The purpose of this paper is the optimization of the tool life and the cutting speed at the drilling of the stainless steels in terms of the maximum productivity. A nonlinear programming model to maximize the productivity at the drilling of a stainless steel is developed in this paper. The optimum cutting tool life and the associated cutting tool speed are obtained by solving the proposed mathematical model. The use of this productivity model allows greater accuracy in the prediction of the productivity for the drilling of a certain stainless steel and getting the optimum tool life and the optimum cutting speed for the maximum productivity. The obtained results can be used in production activity, in order to increase the productivity of the stainless steels machining. Finally the paper suggests new research directions for the specialists interested in this field.

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