Cutting force, tool wear and surface roughness in high-speed milling of high-strength steel with coated tools

2019 ◽  
Vol 33 (11) ◽  
pp. 5393-5398 ◽  
Author(s):  
Yuan Li ◽  
Guangming Zheng ◽  
Xu Zhang ◽  
Xiang Cheng ◽  
Xianhai Yang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
High Strength Steel ◽  
High Speed ◽  
High Strength ◽  
High Speed Milling ◽  
Coated Tools

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

scholarly journals Cutting Performance Evaluation of the Coated Tools in High-Speed Milling of AISI 4340 Steel

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3266 ◽  
Author(s):  
Yuan Li ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Xianhai Yang ◽  
Rufeng Xu ◽  
...  
Keyword(s):  
Performance Evaluation ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Coated Tools ◽  
Coated Tool ◽  
Aisi 4340

The cutting performance of cutting tools in high-speed machining (HSM) is an important factor restricting the machined surface integrity of the workpiece. The HSM of AISI 4340 is carried out by using coated tools with TiN/TiCN/TiAlN multi-coating, TiAlN + TiN coating, TiCN + NbC coating, and AlTiN coating, respectively. The cutting performance evaluation of the coated tools is revealed by the chip morphology, cutting force, cutting temperature, and tool wear. The results show that the serration and shear slip of the chips become more clear with the cutting speed. The lower cutting force and cutting temperature are achieved by the TiN/TiCN/TiAlN multi-coated tool. The flank wear was the dominant wear form in the milling process of AISI 4340. The dominant wear mechanisms of the coated tools include the crater wear, coating chipping, adhesion, abrasion, and diffusion. In general, a TiN/TiCN/TiAlN multi-coated tool is the most suitable tool for high-speed milling of AISI 4340, due to the lower cutting force, the lower cutting temperature, and the high resistance of the element diffusion.

scholarly journals Prediction of Tool Lifetime and Surface Roughness for Nickel-Based Waspaloy

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Shao-Hsien Chen ◽  
Chung-An Yu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Predictive Values ◽  
Actual Surface ◽  
Wide Range

In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.

An intelligent prediction model of the tool wear based on machine learning in turning high strength steel

2020 ◽  
Vol 234 (13) ◽  
pp. 1580-1597
Author(s):  
Minghui Cheng ◽  
Li Jiao ◽  
Xuechun Shi ◽  
Xibin Wang ◽  
Pei Yan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Prediction Model ◽  
Cutting Force ◽  
Surface Quality ◽  
Surface Texture ◽  
High Strength Steel ◽  
Prediction Models ◽  
High Strength ◽  
Support Vector ◽  
Time Frequency

In the process of high strength steel turning, tool wear will reduce the surface quality of the workpiece and increase cutting force and cutting temperature. To obtain the fine surface quality and avoid unnecessary loss, it is necessary to monitor the state of tool wear in the dry turning. In this article, the cutting force, vibration signal and surface texture of the machined surface were collected by tool condition monitoring system and signal processing techniques are being used for extracting the time-domain, frequency-domain and time-frequency features of cutting force and vibration. The gray level processing technique is used to extract the features of the gray co-occurrence matrix of the surface texture and found that these features changed simultaneously when the cutting tool broke. After this, an intelligent prediction model of tool wear was built using the support vector regression (SVR) whose kernel function parameters were optimized by the grid search algorithm (GS), the genetic algorithm (GA) and the particle swarm optimization algorithm respectively. The features extracted from the signals and surface texture are used to train the prediction model in MATLAB. It was found that after the surface texture features were fused using the intelligent prediction model on the basis of the features of cutting force and vibration, prediction accuracy of the proposed method is found as 97.32% and 96.72% respectively under the two prediction models of GA-SVR and GS-SVR. Moreover, the intelligent prediction model can not only predict the tool wear under different cutting conditions, but also the different wear stages in a single wear cycle and the absolute error between the predicted value and the actual value is less than 10 μm, the confidence coefficient of prediction curve is around 0.99.

Wear mechanisms of coated tools in high-speed hard turning of high strength steel

2017 ◽  
Vol 94 (9-12) ◽  
pp. 4553-4563 ◽  
Author(s):  
Guangming Zheng ◽  
Li Li ◽  
Zhiyong Li ◽  
Jun Gao ◽  
Zongwei Niu
Keyword(s):  
Wear Mechanisms ◽  
High Strength Steel ◽  
High Speed ◽  
Hard Turning ◽  
High Strength ◽  
Coated Tools

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Experimental Study in HSM of Hardened Steel AISI D2

2009 ◽  
Vol 69-70 ◽  
pp. 374-378
Author(s):  
B.Y. Qi ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Mechanical Property ◽  
Tool Wear ◽  
High Speed ◽  
Hardened Steel ◽  
Good Mechanical Property ◽  
High Speed Milling ◽  
Milling Parameters ◽  
Coated Tools ◽  
Aisi D2 ◽  
Steel Aisi

Hardened steel is widely used for good mechanical property, but its machinability is bad comparatively. It is efficient to enhance metal removed rate when high speed milling (HSM) hardened steel, but tool wear is rapid. In this paper, high-speed milling experiments were carried out for hardened steel with TiAlN coated tools. The effects of milling parameters on tool wear and surface roughness were studied. The influences of different coolants, such as dry, MQL, cryogenic MQL conditions on HSM hardened steel, were compared with each other, results showed that cryogenic MQL HSM hardened steel had better effects that can better reduce tool wear, extend tool life.

Multi-Objective Optimization Using Box-Behken of Response Surface Methodology for High-Speed Machining of Inconel 718

2014 ◽  
Vol 629 ◽  
pp. 487-492 ◽  
Author(s):  
Mohd Shahir Kasim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
E. Mohamad ◽  
Raja Izamshah ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling

This study was carried out to investigate how the high-speed milling of Inconel 718 using ball nose end mill could enhance the productivity and quality of the finish parts. The experimental work was carried out through Response Surface Methodology via Box-Behnken design. The effect of prominent milling parameters, namely cutting speed, feed rate, depth of cut (DOC), and width of cut (WOC) were studied to evaluate their effects on tool life, surface roughness and cutting force. In this study, the cutting speed, feed rate, DOC, and WOC were in the range of 100 - 140 m/min, 0.1 - 0.2 mm/tooth, 0.5 - 1.0 mm and 0.2 - 1.8 mm, respectively. In order to reduce the effect of heat generated during the high speed milling operation, minimum quantity lubrication of 50 ml/hr was used. The effect of input factors on the responds was identified by mean of ANOVA. The response of tool life, surface roughness and cutting force together with calculated material removal rate were then simultaneously optimized and further described by perturbation graph. Interaction between WOC with other factors was found to be the most dominating factor of all responds. The optimum cutting parameter which obtained the longest tool life of 60 mins, minimum surface roughness of 0.262 μm and resultant force of 221 N was at cutting speed of 100 m/min, feed rate of 0.15 mm/tooth, DOC 0.5 m and WOC 0.66 mm.

Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface

2017 ◽  
Vol 233 (1) ◽  
pp. 18-30 ◽  
Author(s):  
Jian-wei Ma ◽  
Zhen-yuan Jia ◽  
Guang-zhi He ◽  
Zhen Liu ◽  
Xiao-xuan Zhao ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Tool ◽  
Helix Angle ◽  
Curved Surface ◽  
Geometrical Parameters ◽  
High Speed Milling

High-speed machining provides an efficient approach for machining Inconel 718 with high quality and high efficiency. For high-speed milling of Inconel 718 curved surface, the geometrical characteristics are changing continuously leading to a sharp fluctuation of cutting force, which will aggravate the tool wear. As the wear mechanism of coated cutting tool is seriously affected by the cutting tool geometrical parameters, suitable geometrical parameters of cutting tool should be selected to avoid the cutting tool from being worn out very quickly. In this study, the influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface is investigated with coated cutting tool, and the cutting force in milling process is also analyzed. The results show that the cutting force variation can manifest the tool wear degree, and the failure type of coated cutting tool in plane milling and curved surface milling after the same cutting length is different. Furthermore, the cutting tool geometrical parameters seriously affect the tool wear and the tool life in high-speed milling of Inconel 718 curved surface. Concretely, the small rake angle has greater strength and has superiority, the relief angle increasing can enhance the tool life, and the tool life is decreased with the increasing of helix angle for the cutting tool, whose helix angle is larger than 30°. This study provides a theoretical basis for cutting tool wear mechanism and cutting tool geometrical parameter selection in high-speed milling of Inconel 718 curved surface, so as to guarantee the machining efficiency in high-speed milling of Inconel 718 curved surface.

Research on the Influence of Tool Wear on Cutting Performance in High-Speed Milling of Difficult-to-Cut Materials

2016 ◽  
Vol 693 ◽  
pp. 1129-1134
Author(s):  
Zhao Ju Zhu ◽  
Jie Sun ◽  
Lai Xiao Lu
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Variation Trend ◽  
Cutting Tool Wear ◽  
Cutting Vibration

A series of research on the interactions among tool wear, cutting force and cutting vibration were conducted through high speed milling experiment in this paper, which objected the titanium alloy as difficult-to-cut materials. The results showed that the increasing of tool wear led to enlarging the cutting force and cutting vibration; and vice versa, the increasing of cutting force and cutting vibration aggravated the tool wear in the process of machining. Besides, the variation trend of tool wear with cutting was similar to the trend of cutting force, while the variation trend between cutting vibration and tool wear was different. Especially in the sharply cutting tool wear stage, the influence of tool wear on cutting vibration became more complicated.

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