Prediction of Tool Wear Mechanisms in Face Milling AISI 1045 Steel

2011 ◽  
Vol 21 (6) ◽  
pp. 797-808 ◽  
Author(s):  
Patricia Muñoz-Escalona ◽  
Nayarit Díaz ◽  
Zulay Cassier
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Face Milling ◽  
Tool Wear Mechanisms ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Tool Wear Analysis on Multi-Layered Coated Carbide Tools in Face Milling of AISI 1045 Steel

2010 ◽  
Author(s):  
Kyung-Hee Park ◽  
Patrick Y. Kwon
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Face Milling ◽  
Coating Materials ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide ◽  
Coated Carbide Tools ◽  
Layer Coating

Face milling tests on AISI 1045 steel were performed to study the flank wear of multilayered coated carbide tools. The cutting tools were dual (TiN/TiAlN) and triple (TiN/Al2O3/TiCN) layered, coated carbide inserts processed by PVD and CVD respectively. As expected, the depth of cut (DOC) did not play an important role on the development of flank wear while the cutting speed had a significant role in the development of flank wear. Using confocal laser scanning microscopy (CLSM) and wavelet transform, the flank wear evolution was analyzed and abrasive wear was found to be a dominant tool wear mechanism. Adhesion of the work material was also observed after the carbide substrate was exposed. Edge chipping and micro-fracture were additional tool failure modes. After comparing the performance of the two inserts, we concluded that the dual layer coating was superior to the triple layer coating under various cutting conditions mainly due to the benefit coming from the coating processes themselves. It was claimed that the superior performance of the multilayer coating came from preventing the gross crack-induced removal of coating materials by propagating the fracture along the coating interfaces. However, no such observations were found in our milling experiment. Therefore, the hardness of the coating materials is the most important criteria for the development of flank wear.

Performance of wiper geometry carbide tools in face milling of AISI 1045 steel

2018 ◽  
Vol 40 (10) ◽  
Author(s):  
J. V. R. Toledo ◽  
E. M. Arruda ◽  
S. S. C. Júnior ◽  
A. E. Diniz ◽  
J. R. Ferreira
Keyword(s):  
Face Milling ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Tribology of Coated Tools in High-Speed Machining: A Tool Wear and “Equivalent Toolface” Geometry Based Study

2005 ◽  
Author(s):  
A. K. Balaji
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Tool Geometry ◽  
Machining Processes ◽  
Coated Tools ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Rough Turning

Predicting tool-wear (and thereby, tool-life) and selecting proper coated tools along with appropriate tool geometry still remains a major concern for industries trying to achieve increased productivity using automated machining processes. This study is focused upon aggressive high-speed rough turning of AISI 1045 steel. The wear patterns in different coated tools (one mono-layer PVD and two multi-layer CVD coatings) are correlated to changes in nominal tool geometry. This study focuses on the role of tooling geometry (inclination and rake angles) and their importance in dictating the behavior, performance, and wear of coated tools. Using an ‘equivalent toolface’ (ET) model, this study correlates the nominal tool geometry to an equivalent geometry, thereby introducing a new methodology for characterizing the complex effects of multilayer coatings in terms of simple effective tool geometry. The ET approach provides a new angle for understanding the tribological effects of coatings in machining.

Study of the Relationship between Cutting Speed, Tool Wear and Machining Forces in Turning with Carbide Tool

2014 ◽  
Vol 902 ◽  
pp. 88-94
Author(s):  
Heraldo J. Amorim ◽  
Augusto O. Kunrath Neto
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Speed ◽  
Average Error ◽  
Machining Forces ◽  
Feed Force ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
The Relationship

The understanding of machining processes comprises the study of phenomena such as: chip formation, cutting forces, tool wear mechanisms and the influence of the cutting parameters and machined materials on them. The aim of this work is to analyze the tool wear effects on machining forces during machining of AISI 1040 and 1045 carbon steels with carbide tool. Long-term machinability tests were performed, in which cutting force, feed force and tool wear were measured. Tool life results were analyzed, with best tool lives found for the AISI 1040 steel for all tested speeds. The other variables were analyzed as function of both time and tool wear. On the time domain, strong dependencies were found for both materials for tool wear, cutting force and feed force. The relationship between cutting force and tool wear showed good correlation for both materials, and the same was observed for feed force and tool wear relationship. Weak influence of cutting speed was observed on the relationship between tool wear and machining forces, which suggest that a single equation can describe them for all studied conditions with reasonable accuracy. The regression results are able to predict cutting forces as a function of tool wear with an average error of about 2.6 % during machining of AISI 1040 and 5.2 % for AISI 1045 steel. For the prediction of feed force as a function of tool wear, the average error is about 5.6 % for AISI 1040 and 7.0 % for the AISI 1045 steel, since a restricted domain is established. Data analysis showed a discontinuity in the behavior of feed force as a function of tool wear near the end of the life of the tools for most tests performed with AISI 1045 and some tests with AISI 1040 that suggest backwall wear, which was further evidenced by sudden change of chip form near the end of tool life in AISI 1040 steel.

scholarly journals Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771370 ◽  
Author(s):  
Anhai Li ◽  
Jun Zhao ◽  
Guanming Hou
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Wear Mechanisms ◽  
Failure Mechanisms ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Face Milling ◽  
Formation Mechanisms ◽  
Tool Wear Mechanisms ◽  
Cutting Speeds

Chip morphology and its formation mechanisms, cutting force, cutting power, specific cutting energy, tool wear, and tool wear mechanisms at different cutting speeds of 100–3000 m/min during dry face milling of Ti-6Al-4V alloy using physical vapor deposition-(Ti,Al)N-TiN-coated cemented carbide tools were investigated. The cutting speed was linked to the chip formation process and tool failure mechanisms of the coated cemented cutting tools. Results revealed that the machined chips exhibited clear saw-tooth profile and were almost segmented at high cutting speeds, and apparent degree of saw-tooth chip morphology occurred as cutting speed increased. Abrasion in the flank face, the adhered chips on the wear surface, and even melt chips were the most typical wear forms. Complex and synergistic interactions among abrasive wear, coating delamination, adhesive wear, oxidation wear, and thermal mechanical–mechanical impacts were the main wear or failure mechanisms. As the cutting speed was very high (>2000 m/min), discontinuous or fragment chips and even melt chips were produced, but few chips can be collected because the chips easily burned under the extremely high cutting temperature. Large area flaking, extreme abrasion, and serious adhesion dominated the wear patterns, and the tool wear mechanisms were the interaction of thermal wear and mechanical wear or failure under the ultra-high frequency and strong impact thermo-mechanical loads.

Effects of extreme pressure and anti-wear additives on surface topography and tool wear during MQCL turning of AISI 1045 steel

2018 ◽  
Vol 32 (4) ◽  
pp. 1585-1591 ◽  
Author(s):  
Radoslaw W. Maruda ◽  
Grzegorz M. Krolczyk ◽  
Szymon Wojciechowski ◽  
Krzysztof Zak ◽  
Witold Habrat ◽  
...  
Keyword(s):  
Tool Wear ◽  
Surface Topography ◽  
Extreme Pressure ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

scholarly journals Effect of Graphene Addition in Cutting Fluids Applied by MQL in End Milling of AISI 1045 Steel

Lubricants ◽  
2021 ◽  
Vol 9 (7) ◽  
pp. 70
Author(s):  
Vitor Baldin ◽  
Leonardo Rosa Ribeiro da Silva ◽  
Celso Ferraz Houck ◽  
Rogério Valentim Gelamo ◽  
Álisson Rocha Machado
Keyword(s):  
Tool Life ◽  
Wear Mechanisms ◽  
End Milling ◽  
Fatigue Cracks ◽  
Graphene Sheets ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Cemented Carbide

The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting fluids with graphene sheets added and applied via MQL, considering the tool life, wear, and wear mechanisms acting on TiAlN-coated cemented carbide cutting tools in the end milling of AISI 1045 steel. We evaluated two vegetable- (MQL15 and LB1000) and one mineral-based (MQL14) neat oils and the same fluids with the addition of 0.05 and 0.1%wt graphene nanoplatelets. Dry cuts were also performed and investigated for comparison. The experiments were conducted under fixed cutting conditions (vc = 250 m/min, fz = 0.14 mm/tooth, ap = 1 mm, and ae = 20 mm). The end-of-tool-life criterion followed the guidelines of ISO 8688-1 (1989). To analyze the results, ANOVA and Tukey’s test were applied. The addition of graphene sheets in the vegetable-based cutting fluids effectively increased the lubricating properties, partially reducing the wear mechanisms acting on the tools. In addition, there was a predominance of thermal fatigue cracks and mechanical cracks as well as adhesive and abrasive wear mechanisms on the tools used in the cutting with the MQL15 and MQL14 fluids, indicating greater cyclical fluctuations in temperature and surface stresses.

Reducing Tool Wear in CNC End Milling Operation Using Progressive Feed Rate

2014 ◽  
Vol 592-594 ◽  
pp. 716-723
Author(s):  
K.S. Badrinathan ◽  
L. Karunamoorthy
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cnc End Milling

This study focuses on the effect of cutting parameters on the tool wear in a CNC end milling operation. Major factors which influence the tool wear are spindle speed, feed rate and depth of cut. Conventionally constant feed rate is used. In this work a concept of progressive feed rate is introduced. AISI 1045 steel has been chosen as it is widely used in manufacturing. Design of Experiments (DOE) technique was adopted to conduct the experiments. Experiments were conducted for both the existing and the proposed feed rate method and the tool wear was compared. A statistical model was developed using Design Expert software. The predicted values were compared with the experimental values and were found to be in close agreement. The model adequacy was checked using ANOVA technique.

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