Analysis and prediction of tool wear, surface roughness and cutting forces in hard turning with CBN tool

This study focused on the optimization of micro-milling parameters for two extensively used aerospace materials (titanium and nickel-based superalloy). The experiments were planned using Taguchi experimental design method, and the influences of spindle speed, feed rate and depth of cut on machining outputs, namely, tool wear, surface roughness and cutting forces, were determined. Tool wear, surface roughness and cutting forces measured in micro-milling of Ti6Al4V titanium alloy and Inconel 718 workpiece materials were optimized by employing Taguchi’s signal-to-noise ratio. The percentage contribution of micro-milling parameters, namely, spindle speed, feed rate and depth of cut, on tool wear, surface roughness and cutting forces was indicated by analysis of variance. The regression models identifying the relationship between the input variables and the output responses were also fitted using experimental data to predict output responses without conducting the experiments. Efficiency of regression models was determined using correlation coefficients, and the predicted values were compared with experimental results. From results, it was concluded that the established regression models could be employed for predicting tool wear, surface roughness and cutting forces in micro-milling of Ti6Al4V titanium alloy and Inconel 718 workpiece materials.

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Analysis of cutting forces and surface roughness in hard turning of AISI 4340 using multilayer coated carbide tool

International Journal of Machining and Machinability of Materials ◽

10.1504/ijmmm.2014.064687 ◽

2014 ◽

Vol 16 (2) ◽

pp. 169 ◽

Cited By ~ 5

Author(s):

S. Basavarajappa ◽

R. Suresh ◽

V.N. Gaitonde ◽

G.L. Samuel

Keyword(s):

Surface Roughness ◽

Cutting Forces ◽

Hard Turning ◽

Carbide Tool ◽

Coated Carbide Tool ◽

Coated Carbide ◽

Aisi 4340

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Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.382 ◽

2010 ◽

Vol 443 ◽

pp. 382-387 ◽

Cited By ~ 6

Author(s):

Somkiat Tangjitsitcharoen ◽

Suthas Ratanakuakangwan

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Cutting Forces ◽

Cutting Temperature ◽

Cutting Conditions ◽

Cutting Condition ◽

Nose Radius ◽

Dry Cutting ◽

Cnc Turning ◽

Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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