scholarly journals Experimental investigation of the effects of cryogenic cooling on tool life in Ti6Al4V milling

2021 ◽  
Author(s):  
Paolo Albertelli ◽  
Valerio Mussi ◽  
Matteo Strano ◽  
Michele Monno
Keyword(s):  
Tool Life ◽  
Cutting Speed ◽  
Cryogenic Cooling ◽  
Model Parameters ◽  
Cryogenic Milling ◽  
High Cutting Speed ◽  
Cutting Velocity ◽  
Life Tests ◽  
Conventional Cooling ◽  
Cutting Speeds

AbstractIn this paper, the results of an experimental campaign of cryogenic milling are presented and discussed. For this purpose, a specific experimental setup that allowed to feed the liquid nitrogen LN through the tool nozzles was used. Tool life tests were carried out at different cutting speeds. The tool duration data were collected and used to identify the parameters of the Taylor’s model. Different end-of-life criteria for the tool inserts were even investigated. The achieved results are compared to those obtained using conventional cooling. It was observed that at low cutting velocity, conventional cooling still assures longer tool lives than in cryogenic condition. Since in cryogenic milling the increasing of the cutting velocity is not so detrimental as in conventional cutting, at high cutting speed (from 125 m/min) longer tool durations can be achieved. Statistical analyses on the model parameters were carried out to confirm the presented findings. The analysis of the effect of the cooling approach on the main wear mechanisms was also reported. At low cutting speed, adhesion and chipping phenomena affected the tool duration mainly in cryogenic milling.

Tool Life of Coated Tools in Face Milling of GH4169 at Various Cutting Speeds

2013 ◽  
Vol 770 ◽  
pp. 126-129 ◽  
Author(s):  
Xiang Yu Wang ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Qing Ge Zhang ◽  
Han Lian Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
High Cutting Speed ◽  
Coated Tools ◽  
Life Tests ◽  
Material Tool ◽  
Cutting Speeds

GH4169 is widely used in aerospace industry, and it is a typical difficult-to-cut material. Tool life in cutting GH4169 is very low. In this paper, tool life tests of face milling GH4169 were carried out at 30~90m/min with coated tools. The effects of cutting speed and feed rate on the tool life were studied. It was found that the tool life was very sensitive to the cutting speed. And tool failure mode was flank wear at low cutting speed, but turned to tipping at high cutting speed. At last, the suitable cutting parameters were recommended.

scholarly journals Energy assessment of different cooling technologies in Ti-6Al-4V milling

2021 ◽  
Vol 112 (11-12) ◽  
pp. 3279-3306
Author(s):  
Paolo Albertelli ◽  
Michele Monno
Keyword(s):  
Energy Performance ◽  
Primary Energy ◽  
Cryogenic Cooling ◽  
Model Parameters ◽  
Tribological Behaviour ◽  
Dry Cutting ◽  
Sustainable Solutions ◽  
Energy Assessment ◽  
Energy Models ◽  
Conventional Cooling

AbstractManufacturing craves for more sustainable solutions for machining heat-resistant alloys. In this paper, an assessment of different cooling lubrication approaches for Ti6Al4V milling was carried out. Cryogenic cutting (liquid nitrogen) and conventional cooling (oil-based fluid) were assessed with respect to dry cutting. To study the effects of the main relevant process parameters, proper energy models were developed, validated and then used for comparing the analysed cooling lubrication strategies. The model parameters were identified exploiting data from specifically conceived experiments. The power assessment was carried out considering different perspectives, with a bottom-up approach. Indeed, it was found that cryogenic cooling, thanks to a better tribological behaviour, is less energy demanding (at least 25%) than dry and conventional cutting. If the spindle power is considered, lower saving percentages can be expected. Cryogenic cooling showed its best energy performance (from 3 to 11 times) with respect to conventional cutting if the machine tool perspective is analysed. Considering even the primary energy required for producing the cutting fluids, the assessment showed that cryogenic cooling requires up to 19 times the energy required for conventional cutting.

scholarly journals Investigation into Performance of Multilayer Composite Nano-Structured Cr-CrN-(Cr0.35Ti0.40Al0.25)N Coating for Metal Cutting Tools

Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 447 ◽  
Author(s):  
Sergey Grigoriev ◽  
Alexey Vereschaka ◽  
Alexander Metel ◽  
Nikolay Sitnikov ◽  
Filipp Milovich ◽  
...  
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Constructional Steel ◽  
Wear Process ◽  
Layered Architecture ◽  
Process Pattern ◽  
Resistant Layer ◽  
Cutting Speeds

This paper deals with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating. It has a three-layered architecture with a nano-structured wear-resistant layer. The studies involved the investigation into the microstructure (with the use of SEM and TEM), elemental and phase composition (XRD and SAED patterns), wear process pattern in scratch testing, crystal structure, as well as the microhardness of the coating. Cutting tests of tools with the above coating were carried out in dry turning of steel 1045 at cutting speeds of vc = 200, 250, and 300 m·min−1. The comparison included uncoated tools and tools with the commercial TiN and (Ti,Al)N coatings with the same thickness. The tool with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating showed the longest tool life at all the cutting speeds under consideration. Meanwhile, a tool with the coating under study can be recommended for use in turning constructional steel at the cutting speed of vc = 250 m·min−1. At this cutting speed, a tool shows the combination of a rather long tool life and balanced wear process, without any threat of catastrophic wear.

Tool Wear of Polycrystalline Cubic Boron Nitride Compact Tools in Cutting Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 724-728 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Boron Nitride ◽  
Tool Wear ◽  
Tool Life ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Cbn Tool ◽  
High Cutting Speed

Using polycrystalline cubic boron nitride compact (cBN) tools, which have different cBN contents and cBN particle sizes, the influences of both the cBN content and the cBN particle size on tool wear in turning of hardened steel at various cutting speeds was experimentally investigated. Three types of cBN tools (a cBN content of 45-55% and 75%, and a cBN particle size of 0.5 μm and 5 μm, respectively) were tested. Furthermore, three kinds of chamfered and honed cutting edges were also used. The main results obtained are as follows: (1) In the case of the cBN tools with the same cBN particle size of 5.0 μm, the tool life of the cBN tool with a cBN content of 75% was longer than that of the cBN tool with a cBN content of 45% at low cutting speed. However, at high cutting speed, the tool life of the cBN tool with a cBN content of 75% was shorter. (2) The tool life of the cBN tool with both a cBN content of 55% and a cBN particle size of 0.5 μm was the longest. (3) The tool wear of cBN tools decreased with a decrease in chamfer width.

scholarly journals Analysis of the General Tool Life Function of Cutting Tools by Application of the Catastrophe-Theory

2021 ◽  
Author(s):  
Zoltán Pálmai ◽  
János Kundrák ◽  
Csaba Felhő
Keyword(s):  
Tool Life ◽  
Catastrophe Theory ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Taylor Formula ◽  
Technology Planning ◽  
Concave Part ◽  
Cutting Speeds ◽  
General Tool ◽  
Life Function

Abstract Production technology planning requires information on tool life T and its relation to cutting speed v. As the Taylor formula often cannot be linearized on an lg-lg scale, a general tool life function has been developed for describing a v-T function with a convex-concave part. Using catastrophe theory, an analogy is established between the general tool life function and the cusp catastrophe, allowing topological mapping of the general v-T function. Results were verified by machinability tests in the turning of C35 and C60 conventional and specially deoxidized C-steels during steelmaking. It was found that in the convex-concave section of this function, 2–3 cutting speeds can be selected for a given tool life, which is advantageous for harmonizing tool changes in multi-operation technology.

Optimization of High-Precision Reaming Holes with Small Diameters

2013 ◽  
Vol 10 (2) ◽  
pp. 18-21
Author(s):  
Stanislav Fiala ◽  
Karel Kouřil ◽  
Marek Pagáč
Keyword(s):  
Cutting Speed ◽  
Small Diameter ◽  
Operational Reliability ◽  
High Productivity ◽  
High Cutting Speed ◽  
Reduced Costs ◽  
Body Components ◽  
Process Fluid ◽  
Cutting Point ◽  
Cutting Speeds

Abstract In many applications, it is at the final machining precision holes, very advantageous to use a reamer whose cutting portion is made of a cermet, but also other performance materials (PCD, CBN). In these modern tools can be compared with the instruments of conventional cemented carbides apply significantly higher cutting speeds at longer blade life cutting edges. Specific problems and significant demands on the tech-nical design and implementation of these instruments arise from their use for reaming holes with small diameters. Especially in cases where it is required to have high productivity, a high cutting speed and feed. Especially for small diameter tools it is extre-mely difficult to supply the necessary amount of process fluid to the cutting point in real time. A sufficient quantity of liquid will not only provide cooling but also chip. The requirement is to achieve high operational reliability as well as reduced costs using intensive cutting conditions. This situation helps to solve the present structural design of composite reaming tools. Specifically, the optimization of the reamer for reaming holes ø 4,2 H8 with a depth of 8 mm in body components for the automotive industry .

Effect of Stiffness on Tool Wear and New Tool Life Equation

1975 ◽  
Vol 97 (3) ◽  
pp. 939-944 ◽  
Author(s):  
E. Kuljanic´
Keyword(s):  
Statistical Analysis ◽  
Tool Life ◽  
Dynamic Stiffness ◽  
Cutting Speed ◽  
Testing Method ◽  
Number Of Teeth ◽  
Pulse Testing ◽  
Machining System ◽  
Cutting Speeds ◽  
Significant Factors

An investigation of the effect of stiffness of the machining system on tool life with different numbers of teeth in the cutter, cutting speeds, and feeds is described. A statistical analysis was used and the effects of significant factors and interactions were determined. Not only the cutting speed, feed, and number of teeth in the cutter, but also the stiffness and their interactions have a significant effect on tool life. Due to a significant effect of interactions, the effect of the stiffness of machining system depends on the number of teeth in the cutter, cutting speed and feed. A new tool life equation was developed to take this phenomenon in account. The tool life decreases with increasing the number of teeth in the cutter. The static and dynamic stiffness was measured by means of a pulse-testing method which is both simple and reliable in determining the dynamic characteristics of a machining system.

Experimental Analysis of Wear Mechanism and Tool Life in Dry Drilling of Al2024

2012 ◽  
Vol 566 ◽  
pp. 217-221 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Raja Ishak Raja Hamzah ◽  
Abdolkarim Niazi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dry Machining ◽  
Hole Quality ◽  
High Cutting Speed

Aluminum alloy is widely used in industry and various researches has been done on machiability of this material mainly due to its low weight and other superior properties. Dry machining is still interesting topic to reduce the cost of manufacturing and environmental contaminations. In present study dry machining of Al 2024 investigated on tool life, tool wear mechanisms, hole quality, thrust force and torque. Different types of high speed steel (HSS) tools utilized at constant feed rate of 0.04 mm/rev and cutting speeds within the range of 28 and 94 m/min. Experimental results revealed that HSCo drills, performed better than HSS drills in terms of tool life and hole quality. The main wear mechanisms which analyzed by scanning electron microscope found abrasive and adhesion wear on flank face, besides, BUE observed at chisel and cutting edges. However tool wear and BUE formation found more significant at high cutting speed. In terms of thrust force, two facet HSCo tools, recorded higher thrust force than four facet HSS drills.

The Effect of Cutting Speed on Chip Formation Under Orthogonal Machining

1985 ◽  
Vol 107 (1) ◽  
pp. 55-63 ◽  
Author(s):  
D. Lee
Keyword(s):  
Chip Formation ◽  
Cutting Speed ◽  
Chip Morphology ◽  
High Cutting Speed ◽  
Orthogonal Machining ◽  
Localized Heating ◽  
On Chip ◽  
All Speeds ◽  
Cutting Speeds ◽  
Steel Chip

Orthogonal machining experiments were conducted at different cutting speeds ranging from 8.5 × 10−2 cm/s (0.17 ft/min) to about 2.5 × 102 cm/s (492.1 ft/min) with 6061-T6 aluminum, 4340 steel, and Ti-6A1-4V titanium to examine the chip formation process. The most pronounced effect of the cutting speed on chip morphology was observed with the titanium alloy; the chips remained segmented at all speeds, but became continuous macroscopically at high cutting speeds. The steel chip also became continuous and oxidized, showing the effect of localized heating. The changing chip morphology that is accompanied with decreasing normal force at the high cutting speed is rationalized on the basis of localized adiabatic heating, which is dependent on the thermal-mechanical properties of each material.

scholarly journals Vibration assisted cutting of Gouda cheese

2012 ◽  
Vol 30 (No. 1) ◽  
pp. 1-8
Author(s):  
A. Lebar ◽  
O. Blatnik ◽  
M. Junkar ◽  
H. Orbanić
Keyword(s):  
Cutting Force ◽  
Vibration Frequency ◽  
Cutting Forces ◽  
Research Work ◽  
Cutting Speed ◽  
Vibration Frequencies ◽  
Cheese Sample ◽  
Cutting Velocity ◽  
Gouda Cheese ◽  
Cutting Speeds

The influence of vibrations on the process of cheese cutting applied in order to reduce friction and the cutting force was studied. The forces needed to cut through the cheese samples were measured against the variations of the temperature, cutting speed, and vibration frequency. The hypothesis which induced the research work was that assisting vibrations reduce the cutting forces and make the cutting easier for the user. In the experiments,Goudacheese was used at 10°C and 22°C. The further, a conventional kitchen knife was used with four different cutting speeds from 12.5 mm/s to 75 mm/s and six vibration frequencies from 0 Hz to 150 Hz. The results confirmed the hypothesis presuming that up to 3.4 times lower forces are needed to cut through a cheese sample at 22°C, and 1.55 times lower when cutting cheese samples at 10°C. The results also confirmed the already known facts that the cutting forces increase with increasing cutting velocity, 2–4 times on average with cutting at 75 mm/s instead of 12.5 mm/s. Also, 2.5, times lower cutting forces were measured in cutting the cheese sample at 22°C instead at 10°C.  

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