On tool wear and its effect on machined surface integrity

1990 ◽  
Vol 8 (4) ◽  
pp. 255-265 ◽  
Author(s):  
Qufei Xie ◽  
Abdel E. Bayoumi ◽  
L. Alden Kendall
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Machined Surface ◽  
Machined Surface Integrity

scholarly journals Effects of Tool Wear on Machined Surface Integrity During Milling of Inconel 718

2021 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Minchao Cui ◽  
Xuehong Shen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machined Surface Integrity

Abstract This paper investigates the effects of tool wear on the machined surface integrity characteristics, including the surface roughness, surface topography, residual stress, microhardness and microstructure, during ball-end milling of Inconel 718. Tool wear, tool lifetime, and cutting force are measured. In addition, a two-dimensional finite element-based model is developed to investigate the cutting temperature distribution in the chip–tool–workpiece contact area. Results show that the ball nose end mill achieves tool lifetime of approximately 350 min. The cutting forces increase sharply with a greater tool flank wear width, while the highest cutting temperature has a decreasing tend at a flank wear width of 0.3 mm. Higher tool flank wear width produces larger surface roughness and deteriorative surface topography. A high-amplitude (approximately −700 MPa) and deep layer (approximately 120 mm) of compressive residual stress are induced by a worn tool with 0.3 mm flank wear width. The surface microhardness induced by new tool is larger than that induced by worn tool. Plastic deformation and strain streamlines are observed within 10 mm depth beneath the surface. The results in this paper provide an optimal tool wear criterion which integrates the surface integrity requirements and the tool lifetime for ball-end finish milling of Inconel 718.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Study on Surface Integrity in Hard Milling of Hardened Die Steel

2006 ◽  
Vol 532-533 ◽  
pp. 540-543 ◽  
Author(s):  
Lu Lu Jing ◽  
Gang Liu ◽  
Ming Chen
Keyword(s):  
Residual Stress ◽  
Tool Wear ◽  
Surface Integrity ◽  
Cutting Tools ◽  
Longitudinal Direction ◽  
Negative Influence ◽  
Practical Significance ◽  
Hard Milling ◽  
Machined Surface ◽  
Die Steel

In die and mold industry, there is a tendency to use milling in the finishing machining of dies and molds as an alternative to the traditional EDM process, consequently the surface integrity in milling is considered as one of the most important indices. In this study, surface roughness, micrograph of machined surface, surface microhardness, residual stress, and metallurgical texture of the surface layer were considered. The influence of geometrical characteristics of cutting tools and tool wear on surface integrity was studied. The results showed that hard milling of hardened die steel could yield a quite satisfied surface integrity by proper process; compressive residual stress was induced on machined surface, and the compressive stress induced in transversal direction was almost 3 times of that in longitudinal direction; tool wear had a significant negative influence on surface finish and caused the machined surface soften. These conclusions revealed the effects of tool conditions on surface integrity and would play a practical significance in the machining of hardened die steel.

Surface Integrity of Die Material in High Speed Hard Machining, Part 1: Micrographical Analysis

1999 ◽  
Vol 122 (4) ◽  
pp. 620-631 ◽  
Author(s):  
T. I. El-Wardany ◽  
H. A. Kishawy ◽  
M. A. Elbestawi
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
Tool Steel ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Conditions ◽  
Metallographic Analysis ◽  
Tool Geometry ◽  
Machined Surface ◽  
Geometrical Defects

The effects of cutting conditions and tool wear on chip morphology and surface integrity during high speed machining of D2 tool steel (60–62 Hrc) are investigated experimentally and analytically in this paper. Polycrystalline Cubic Boron Nitride (PCBN) tools are used in this investigation. The chips and the subsurface of the workpiece are examined using optical and scanning electron microscopy. Microhardness measurements are performed on the surface and subsurface of the workpiece. The X-ray diffraction technique is used to measure the residual stresses induced in the machined surface. The paper is divided into two parts. Part 1 presents the results obtained from the micrographical analysis of the chips and the surfaces produced. Part 2 deals with microhardness and residual stresses of the machined surface. The micrographical analysis of the chips produced shows that different mechanisms of chip formation exist depending on the magnitude of the cutting pressure and tool wear. Saw toothed chips are produced during the machining of D2 tool steel if the cutting pressure exceeds approximately 4000 MPa. The metallographic analysis of the surface produced illustrates the damaged surface region that contains geometrical defects and changes in the subsurface metallurgical structure. The types of surface damage are dependent on the cutting conditions, tool geometry and the magnitude of the wear lands. [S1087-1357(00)00104-0]

scholarly journals Effect of Machined Surface Integrity on Fatigue Performance of Metal Workpiece: A Review

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Guoliang Liu ◽  
Chuanzhen Huang ◽  
Bin Zhao ◽  
Wei Wang ◽  
Shufeng Sun
Keyword(s):  
Residual Stress ◽  
Surface Topography ◽  
Surface Integrity ◽  
Work Hardening ◽  
Fatigue Cracks ◽  
Fatigue Performance ◽  
Effective Control ◽  
Published Data ◽  
Machined Surface ◽  
Machined Surface Integrity

AbstractFatigue performance is a serious concern for mechanical components subject to cyclical stresses, particularly where safety is paramount. The fatigue performance of components relies closely on their surface integrity because the fatigue cracks generally initiate from free surfaces. This paper reviewed the published data, which addressed the effects of machined surface integrity on the fatigue performance of metal workpieces. Limitations in existing studies and the future directions in anti-fatigue manufacturing field were proposed. The remarkable surface topography (e.g., low roughness and few local defects and inclusions) and large compressive residual stress are beneficial to fatigue performance. However, the indicators that describe the effects of surface topography and residual stress accurately need further study and exploration. The effect of residual stress relaxation under cycle loadings needs to be precisely modeled precisely. The effect of work hardening on fatigue performance had two aspects. Work hardening could increase the material yield strength, thereby delaying crack nucleation. However, increased brittleness could accelerate crack propagation. Thus, finding the effective control mechanism and method of work hardening is urgently needed to enhance the fatigue performance of machined components. The machining-induced metallurgical structure changes, such as white layer, grain refinement, dislocation, and martensitic transformation affect the fatigue performance of a workpiece significantly. However, the unified and exact conclusion needs to be investigated deeply. Finally, different surface integrity factors had complicated reciprocal effects on fatigue performance. As such, studying the comprehensive influence of surface integrity further and establishing the reliable prediction model of workpiece fatigue performance are meaningful for improving reliability of components and reducing test cost.

Investigation on mechanism of chip formation and machined surface integrity in orthogonal cutting of metallic materials

2003 ◽  
Vol 2003.40 (0) ◽  
pp. 275-276
Author(s):  
Tamaki OHBAYASHI ◽  
Noboru MORITA ◽  
Shigeru YAMADA ◽  
Noboru TAKANO ◽  
Tatsuo OYAMA
Keyword(s):  
Surface Integrity ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Metallic Materials ◽  
Machined Surface ◽  
Machined Surface Integrity
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