Cutting force modeling considering tool wear effect during turning of hardened AISI 4340 alloy steel using multi-layer TiCN/Al2O3/TiN-coated carbide tools

2015 ◽  
Vol 83 (9-12) ◽  
pp. 1749-1762 ◽  
Author(s):  
Satish Chinchanikar ◽  
S. K. Choudhury
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Alloy Steel ◽  
Force Modeling ◽  
Coated Carbide ◽  
Coated Carbide Tools ◽  
Aisi 4340

scholarly journals PENGARUH GAYA POTONG PEMBUBUTAN TERHADAP KEAUSAN PAHAT KARBIDA COATED PADA BENDA KERJA BAJA AISI 4340

POROS ◽  
2018 ◽  
Vol 16 (1) ◽  
Author(s):  
Rosehan Rosehan Rosehan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Alloy Steel ◽  
Tool Life ◽  
Cutting Tools ◽  
Machining Process ◽  
Maximum Value ◽  
Trial Analysis ◽  
Steel Aisi ◽  
Aisi 4340

Cutting force and tool life is the important data in planning a machining process. The research is in order to describe about the influence of the cutting force to the tool wear on carbide coated cutting tools used the turning process of an alloy steel of AISI 4340. The research was conducted by observing the growth of tool wear on minutes 4.5, 9, 13.5, 18, 22.5 with the maximum value VB 0.3 mm, at the same time, the condition of other cutting such as the motion while the cutting, the depth and speed of the cutting movement was constant. The purpose of this experiment is to examine scientifically the influence cutting force to the growth of tool wear on carbide coated while the cutting process of alloy steel AISI 4340. The graphical method was used for the trial analysis, to see the cutting force comparison with the decrease of tool life of the carbide coated, and the correlation of the cutting movement with the cutting force. The mechanism decrease showed the adhesion decrease.

Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

2010 ◽  
Vol 33 ◽  
pp. 173-176
Author(s):  
X.Y. Wang ◽  
S.Q. Pang ◽  
Q.X. Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Experimental Research ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Life Testing ◽  
Processing Efficiency ◽  
Comparative Tests ◽  
Coated Carbide ◽  
Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

High-Quality End Milling of CFRP – Inclination Milling with High-Helix End Mill –

2016 ◽  
Vol 10 (3) ◽  
pp. 372-380 ◽  
Author(s):  
Akira Hosokawa ◽  
◽  
Naoya Hirose ◽  
Takashi Ueda ◽  
Tomohiro Koyano ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Integrity ◽  
Helix Angle ◽  
Surface Generation ◽  
End Mill ◽  
Side Milling ◽  
Pull Out ◽  
End Mills ◽  
Coated Carbide

Side milling tests of CFRP (carbon fiber reinforced plastics) containing thermosetting resin are carried out by TiAlN/AlCrN-coated, H2-free DLC (diamond-like carbon)-coated, and CVD diamond-coated carbide end mills without coolant. Two types of end mills having different helix angles of 30° and 60° are used. The film thickness and surface smoothness are varied for the DLC-coated end mills. The cutting characteristics are evaluated by tool wear and surface integrity (i.e., 3D profiles of the machined surface, generation of fluffing, delamination, and pull-out of the carbon fibers). The cutting force and tool flank temperature are also examined for the two types of CFRP composites and the helix angle of the end mill. “Inclination milling,”in which the end mill is tilted so that the resultant cutting force acts parallel to the work surface, is proposed as a novel technique to be used with a high-helix angle end mill. This unique approach enables the reduction of tool wear and improves the surface integrity of machined CFRP surfaces.

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