Evolution of cutting forces and tool failure mechanisms in intermittent turning of hardened steel with ceramic tool

2016 ◽  
Vol 89 (5-8) ◽  
pp. 1603-1613 ◽  
Author(s):  
Feng Gong ◽  
Jun Zhao ◽  
Jiming Pang
Keyword(s):  
Cutting Forces ◽  
Failure Mechanisms ◽  
Hardened Steel ◽  
Ceramic Tool ◽  
Tool Failure ◽  
Intermittent Turning

Failure analysis of ceramic tool in intermittent turning of hardened steel

2017 ◽  
Vol 232 (12) ◽  
pp. 2140-2153 ◽  
Author(s):  
Xiuying Ni ◽  
Jun Zhao ◽  
Fuzeng Wang ◽  
Feng Gong ◽  
Xin Zhong ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Failure Modes ◽  
Failure Mechanisms ◽  
Cutting Tools ◽  
Transient Temperature ◽  
Ceramic Tool ◽  
Tool Failure ◽  
Fracture Modes ◽  
Intermittent Turning ◽  
Cutting Speeds

The aim of this investigation is to identify the Al2O3-(W, Ti)C ceramic fracture modes and failure mechanisms under different cutting speeds and feed rates during intermittent turning of hardened 20CrMnTi steel. The failure surfaces of the cutting tools were examined by digital optical microscope and scanning electron microscope. The cutting forces and transient temperature in the intermittent turning process were measured during the entire life cycle. The experimental results showed that the cutting forces exhibited an increasing trend with the tool failure progression, which in turn accelerated the tool failure progression. The main failure modes of ceramic tools were wear and micro-chipping in the initial stage and final fractures, resulting from mechanical damage and thermal damage in intermittent turning processes. And the cutting temperature increased with the increase in cutting speed. The cutting speeds and feed rates were closely correlated with ceramic tool fracture modes and failure mechanisms. Furthermore, the combination of cutting parameters was divided into four regions with different fracture modes and failure mechanisms of cutting tools according to the fracture morphology of cutting tools. This partitioning analysis can provide a basis for the design and development of different ceramic cutting tools with the desired properties for different applications.

Self-Sharpening Failure Characteristic of a Si3N4 Ceramic Tool in High Speed Cutting of Inconel 718

2016 ◽  
Vol 693 ◽  
pp. 1135-1142 ◽  
Author(s):  
Guang Ming Zheng ◽  
Jun Zhao ◽  
Xiang Cheng ◽  
Min Wang
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Adhesive Wear ◽  
Failure Mechanisms ◽  
Cutting Edge ◽  
Ceramic Tool ◽  
Tool Failure ◽  
High Speed Cutting ◽  
Failure Characteristic ◽  
Failure Evolution

A Si3N4 ceramic tool material with high mechanical properties was fabricated by hot-pressing sintering process. The high speed machining of Inconel 718 tests were carried out with round ceramic inserts. The failure surface and microstructure were analyzed by scanning electron microscopy (SEM) to reveal the ceramic tool failure mechanisms. The results showed that the main failure mechanisms of the Si3N4 ceramic tool were flaking, micro-chipping, abrasive wear and adhesive wear in the turning process. On the other hand, chipping, flaking and adhesive wear were the main failure reasons in the milling process. Meanwhile, some small flaking along the cutting edge and step-shaped flaking on the rake face closed to the cutting edge were found on the failure surfaces, which was a typical self-sharpening failure characteristic of the ceramic tool in the high-speed cutting process. This tool failure evolution characteristic of the ceramic tool can be attributed to its higher flexural strength and fracture toughness, which was beneficial to improve the tool life and was constrained by cutting conditions.

scholarly journals A Study on Endmilling of Hardened Steel. (1st Report). Simplified Prediction Model for Cutting Forces and Control for Constant Cutting Foces Using this Model.

2000 ◽  
Vol 66 (5) ◽  
pp. 730-734 ◽  
Author(s):  
Yoshiaki KAKINO ◽  
Hirotoshi OHTSUKA ◽  
Heisaburo NAKAGAWA ◽  
Toshiki HIROGAKI ◽  
Masashi SASAKI
Keyword(s):  
Prediction Model ◽  
Cutting Forces ◽  
Hardened Steel ◽  
And Control

Progressive Tool Failure in High Speed End Milling of Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 32-37 ◽  
Author(s):  
An Hai Li ◽  
Jun Zhao ◽  
Z.Q. Pei ◽  
S.G. Guo
Keyword(s):  
Abrasive Wear ◽  
Inconel 718 ◽  
Adhesive Wear ◽  
End Milling ◽  
Failure Mechanisms ◽  
Cutting Speed ◽  
Fatigue Wear ◽  
Edge Chipping ◽  
Tool Failure ◽  
Coated Carbide

The failure progression of coated carbide tools in end milling of Inconel 718 superalloy was investigated. Tool wear was measured and failure mechanisms were discussed in the experimental process periodically. The experimental results indicated that the tool failure mechanisms were synergistic interaction among abrasive wear, adhesive wear, and fatigue wear. However, abrasive wear and adhesive wear were the main failure mechanisms at the beginning, fatigue wear prevailed the upper hand around the time when edge chipping appeared, and after edge chipping abrasive wear and adhesive wear dominated until the failure time. In addition, the macroscopic failure of the cutting tools is closely correlated to the nucleation and propagation of the crack under cyclic mechanical and thermal impact forces. Mechanical fatigue wear was the key form of fatigue wear at lower cutting speed, while at higher cutting speed thermal fatigue wear was the dominant fatigue wear.

Cutting Performance and Tool Failure in Intermittent Turning Processes of an Al2O3-Based Micro-Nano-Composite Ceramic Tool

2012 ◽  
Vol 723 ◽  
pp. 56-61
Author(s):  
Yong Hui Zhou ◽  
Jun Zhao ◽  
Xiao Bin Cui
Keyword(s):  
Failure Modes ◽  
Composite Ceramic ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Nano Composite ◽  
Micro Particles ◽  
Intermittent Turning ◽  
Shock Resistance ◽  
1045 Steel

An Al2O3-based micro-nano-composite ceramic cutting tool material reinforced with (W, Ti)C micro-particles and Al2O3 micro-nano-particles was fabricated by using hot-pressing technique, the composite was denoted as AWT. The cutting performance, failure modes and mechanisms of the AWT micro-nano-composite ceramic tool were investigated via intermittent turning of hardened AISI 1045 steel (44~48 HRC) in comparison with those of an Al2O3/(W, Ti)C micro-composite ceramic tool SG-4 and a cemented carbide tool YS8. Worn and fractured surfaces of the cutting tools were characterized by scanning electron microscopy (SEM). The results of intermittent turning revealed that shock resistance of the AWT ceramic tool was higher than that of the SG-4 and YS8 tools at all the tested cutting speeds. The excellent shock resistance of the AWT composite ceramic tool was attributed to its synergistic strengthening/toughening mechanisms induced by the (W, Ti)C micro-particles and Al2O3 nano-particles.

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