The Study on Interrupted Cutting Tool Life of Coated Carbide and CBN in Ductile Cast Iron

Wear behavior of WC based nanocomposite cutting tool when high speed cutting ductile cast iron was investigated. Orthogonal cutting tests were carried out on a CA6140 lathe using three speeds, namely, 100, 215 and 287m min-1. The WC based nanocomposite tool is found to be superior to cemented carbide tools (YG8). The tool life is prolonged 60% as compared to cemented carbide, as the width of the wear land (VB), which was monitored at selected time intervals. Meanwhile, the topography of worn surfaces was scanned by a profilemeter. Wear characterization of the rake face and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM). Results showed that distinctive traces of single abrasive tool wear event were found on the rake face of the tool, additionally, the adhesion wear is the main wear mechanism in the flank face of the tool. However, the extent of improvement in tool life depends strongly on the cutting conditions, with the greatest benefits being seen at higher cutting speeds and feed rates.

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Application of FEM in Investigating Machining Performance

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1033 ◽

2011 ◽

Vol 264-265 ◽

pp. 1033-1038

Author(s):

Hendri Yanda ◽

Jaharah A. Ghani ◽

Che Hassan Che Haron

Keyword(s):

Cast Iron ◽

Cutting Force ◽

Cutting Tool ◽

Rake Angle ◽

Ductile Cast Iron ◽

Machining Performance ◽

Stress Strain ◽

Clearance Angle ◽

Tool Geometries ◽

Carbide Insert

The two biggest problems that often experienced in machining cast iron are poor machinability and high hardness. Up to now, many researchers have investigated machining performance and how to find optimum condition in machining ductile cast iron. This study aims to investigate the machining performance of ductile cast iron and carbide cutting tool using FEM. Performances were evaluated by changing the cutting tool geometries on the machining responses of cutting force, stress, strain, and generated temperature on the workpiece. Deform-3D commercial finite element software was used in this study. Ductile cast iron FCD 500 grade was used as the work piece material and carbide insert DNMA432 type with WC (Tungsten) was used for the cutting tool. The effects of rake and clearance angles were investigated by designing various tool geometries. Various combination of carbide insert geometries were designed using Solid Work to produce +15, +20 and +30 deg for rake angle and 5, 7, 8 and 9 deg for clearance angle. Machining condition for the simulations were remained constant at cutting speed of 200 m/min, feed rate of 0.35 mm/rev, and depth of cut of 0.3 mm. The results of effective-stress, strain and generated temperature on both chip and material surface were analysed. The results show that by increasing the rake angle (α), it will improves the machining performance by reducing the cutting force, stress, strain and generated temperature on surface of workpiece. But, by increasing the clearance angle (γ), it will not affect much to the cutting force, stress, strain and generated temperature on chip.

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Comparison of coated carbide cutting tool inserts used in machining of cylinder liners made of grey cast iron

MANUFACTURING TECHNOLOGY ◽

10.21062/ujep/x.2009/a/1213-2489/mt/9/1/23 ◽

2009 ◽

Vol 9 (1) ◽

Cited By ~ 2

Author(s):

Jiří Čuban ◽

Jaroslav Kovalčík

Keyword(s):

Cast Iron ◽

Cutting Tool ◽

Grey Cast Iron ◽

Carbide Cutting Tool ◽

Grey Cast ◽

Cylinder Liners ◽

Coated Carbide

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Wear Behavior of Multilayer Nanocomposite TiAlSiN/TiSiN/TiAlN Coated Carbide Cutting Tool during Face Milling of Inconel 718 Superalloy

Journal of Nano Research ◽

10.4028/www.scientific.net/jnanor.47.11 ◽

2017 ◽

Vol 47 ◽

pp. 11-16 ◽

Cited By ~ 8

Author(s):

Bilal Kursuncu ◽

Halil Caliskan ◽

Sevki Yilmaz Guven ◽

Peter Panjan

Keyword(s):

Tool Life ◽

Inconel 718 ◽

Cutting Tool ◽

Elevated Temperatures ◽

Wear Behavior ◽

Cutting Tools ◽

Face Milling ◽

Carbide Cutting Tool ◽

Inconel 718 Superalloy ◽

Coated Carbide

The Inconel 718 superalloy is one of the most-used nickel based superalloys in the aerospace industry due to its superior mechanical properties, for instance, high thermal and chemical resistance, and high strength at elevated temperatures. However, the work hardening tendency, low thermal conductivity and high hardness of this superalloy cause early tool wear, leading to the material to be called as a hard-to-cut material. Therefore, deposition of a wear resistant hard coating on carbide cutting tools has a critical importance for longer tool life in milling operations of the Inconel 718 superalloy. In this study, carbide cutting tools were coated with multilayer nanocomposite TiAlSiN/TiSiN/TiAlN coating using the magnetron sputtering technique, and wear behavior of the coated tool was investigated during face milling of the Inconel 718 superalloy under dry conditions. Abrasive and adhesive wear mechanisms were founded as main failure mechanisms. The nanocomposite TiAlSiN/TiSiN/TiAlN coated carbide cutting tool gave better wear resistance, and thus it provided 1.7 times longer tool life and a smoother surface (Ra<0.18 μm) on the Inconel 718 material than the uncoated one.

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Damage of PVD-Coated Cutting Tools Due to Interrupted Cutting of Ni-Based Superalloys

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.656-657.191 ◽

2015 ◽

Vol 656-657 ◽

pp. 191-197 ◽

Cited By ~ 6

Author(s):

Shuho Koseki ◽

Kenichi Inoue ◽

Kazutake Uehara ◽

Hiroshi Usuki ◽

Masahiro Yoshinobu ◽

...

Keyword(s):

Electron Microscopy ◽

High Temperatures ◽

Tool Life ◽

Cross Sections ◽

Cutting Tools ◽

Friction Forces ◽

Interrupted Cutting ◽

Transmission Electron ◽

End Mills ◽

Coated Carbide

Ni-based superalloys are typically difficult-to-cut materials. During machining, the cutting forces and temperatures of these superalloys are generally higher than those of other materials. Therefore, the tool life of the coated carbide cutting tools used for superalloy machining is shortened. This study evaluates the damage of the coated end mills during interrupted cutting of alloy 718 and finds the coating properties necessary for improved cutting of Ni-based superalloys. Damage of the PVD-TiN-coated cutting tools was observed by scanning electron microscopy and transmission electron microscopy of the surfaces and cross sections. In addition, friction forces were measured during turning for some coatings, and hardness of the coatings was measured after annealing. Plastic deformation of the coating and crack formation was shown to occur at the coating cross section. In addition, we determined that the major factor for the damage was high friction force between the coating surface and work material at high temperatures. In summary, coatings with stability at high temperatures and low friction forces during machining can reduce the damage of coated cutting tools, thus increasing the tool life.

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Influence of the Coated Carbide Grade on the Cutting Tool Life When Machining Inconel 718

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.674.271 ◽

2016 ◽

Vol 674 ◽

pp. 271-276

Author(s):

Tomáš Bakša ◽

Michal Morávek ◽

Miroslav Zetek

Keyword(s):

Tool Life ◽

Inconel 718 ◽

Cutting Tool ◽

Cutting Tools ◽

High Heat ◽

Nuclear Industry ◽

Inconel 718 Alloy ◽

The Right ◽

Coated Carbide ◽

Milling Tools

This article deals with the machining of Inconel 718 alloy. In the research, several carbide milling tools with different carbide grades and coatings were used. The main aim is compare all cutting tools in terms of their cutting tool life during machining super alloy Inconel 718. This material is used for highly stressed components in the nuclear industry, such as combustion turbine. Due to its rapid hardening and high heat generation, it is very problematic to machining. The right choice of appropriate carbide grade is necessary to achieve high-quality cutting wedge, which is important for good adhesion of the coating. The results of this work will be used for further research and development of cutting tools for machining Inconel 718.

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Tool Life and Surface Roughness of FCD 700 Ductile Cast Iron when Dry Turning Using Carbide Tool

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.126-128.347 ◽

2010 ◽

Vol 126-128 ◽

pp. 347-352

Author(s):

Jaharah A. Ghani ◽

Mohd Nor Azmi Mohd Rodzi ◽

Kamal Othman ◽

Che Hassan Che Haron

Keyword(s):

Surface Roughness ◽

Cast Iron ◽

Tool Life ◽

Feed Rate ◽

Cutting Speed ◽

Ductile Cast Iron ◽

Depth Of Cut ◽

Carbide Tool ◽

High Cutting Speed ◽

High Feed

Machining is one of the most important processes in producing automotive component such as difficult-to-cut FCD700 cast iron grade. Efforts are continuously made to improve the machining technique for the benefit of human and environment. This paper presents an environmental friendly when turning FCD700 cast iron using carbide tool in the absent of coolant. The turning process was carried out in three medium of dry conditions i.e. without air, chilled air and normal air. The turning parameters studied were cutting speed (100-300 m/min), feed rate (0.1-0.4 mm/rev), and depth of cut (0.2-2.0 mm). Result shows that the average surface roughness (Ra) was greatly affected by the feed rate and the effect of depth of cut was negligible. Low Ra value was produced when using high cutting speed, especially at medium air temperature of 10 deg C. Whereas when turning at high depth of cut and high feed rate, the tool life was shorten drastically. In addition, the cutting speed was significantly affecting the tool life. The tool life was found to be inversely proportional with the cutting speed. The longest tool life was obtained at cutting speed of 100 m/min, feed rate of 0.15 mm/rev, depth of cut of 0.2 mm and temperature of -2 deg C. Generally, chilled air at temperature of -2deg C will increase the tool life, but the Ra obtained was deteriorated when compared at higher temperature of chilled air and without air cutting environment. Therefore, these findings can be used a guide depending on the preference of the user, either to obtain a better tool life or Ra value.

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Green Turning of FCD 700 Ductile Cast Iron Using Coated Carbide Tool

10.1063/1.3510552 ◽

2010 ◽

Cited By ~ 3

Author(s):

Mohd Nor Azmi Mohd Rodzi ◽

Jaharah A. Ghani ◽

A. M. Eghawail ◽

Kamal Othman ◽

Mohd. Nizam Ab. Rahman ◽

...

Keyword(s):

Cast Iron ◽

Ductile Cast Iron ◽

Carbide Tool ◽

Coated Carbide Tool ◽

Coated Carbide

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TOOL LIFE PERFORMANCE OF COATED CARBIDE TOOL ON TITANIUM ALLOY EXTRA LOW INTERSTITIALS

Jurnal Teknologi ◽

10.11113/jt.v77.4107 ◽

2015 ◽

Vol 77 (1) ◽

Author(s):

R. Zuraimi ◽

M. A. Sulaiman ◽

T. Joseph Sahaya Anand ◽

E. Mohamad ◽

C. H. Che Haron

Keyword(s):

Tool Life ◽

Feed Rate ◽

Cutting Tool ◽

Flank Wear ◽

Cutting Speed ◽

Weight Ratio ◽

Chemical Vapor ◽

Corrosion Property ◽

Depth Of Cut ◽

Coated Carbide

The Titanium alloys (Ti-6Al-4V) has been employed in a variety of applications, particularly in the aerospace, automotive, medical and chemical industries, primarily because of its high strength to weight ratio, high resistance to fracture, and exceptional anti-corrosion property. However, Ti-6Al-4V cannot be easily machined even at a high temperature as it has a low thermal conductivity and low elastic modulus, and may react chemically with the coating on the cutting tool. The objective of this study was to investigate the cutting tool life performance in the turning of Ti-6Al-4V Extra Low Interstitials (ELI) using a Chemical Vapor Deposition (CVD) carbide cutting tool in dry conditions. The Factorial method was used as the basis for the experimental design of this study. A factorial design with two levels was chosen for the arrangement of the cutting parameters, which comprised a cutting speed of between 100 to 140 m/min, a feed rate of between 0.15 to 0.20 mm/rev, and a fixed depth of cut of 0.35 mm. A three-axis microscope was used to measure the flank wear for every 20 mm on the workpiece until the ISO criterion was arrived at by the flank wear (Vb). The results indicated that the maximum tool life of 20.68 minutes was achieved at a cutting speed of 100 m/min and a feed rate of 0.15 mm/rev.

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