Machining of Inconel 718 Using Coated WC Tool: Effects of Cutting Speed on Chip Morphology and Mechanisms of Tool Wear

2019 ◽  
Vol 45 (2) ◽  
pp. 797-816
Author(s):  
Merugu Rakesh ◽  
Saurav Datta
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Chip Morphology ◽  
On Chip

Experimental Investigation of Tool Wear and Chip Morphology in Turning Titanium Alloy Ti6Al4V

2014 ◽  
Vol 800-801 ◽  
pp. 81-86
Author(s):  
Zhen Li ◽  
Er Liang Liu ◽  
Teng Da Wang ◽  
Jiao Li ◽  
Yong Chun Zheng
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Adhesion Wear ◽  
On Chip ◽  
Titanium Alloy Ti6al4v ◽  
Cutting Experiments

The various feed rate and cutting speed have an important influence on cutting force, tool wear and chip morphology in machining titanium alloy. Cutting experiments are carried out analyzing the titanium alloy Ti6Al4V under different cutting speed and feed rate, the cutting force values are obtained. The analysis results show that the dominant wear pattern is adhesion wear and chipping. And the tool wear also has an influence on chip morphology.

Thermal-Mechanical Effect on Temperature/Stress Distribution when Orthogonal Cutting Bearing Steel

2009 ◽  
Vol 407-408 ◽  
pp. 420-423
Author(s):  
He Ping Wang ◽  
Xue Ping Zhang
Keyword(s):  
Stress Distribution ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Bearing Steel ◽  
Mechanical Effect ◽  
Arbitrary Lagrangian Eulerian ◽  
Calculation Results ◽  
On Chip ◽  
Explicit Dynamic

An explicit dynamic coupled thermal-mechanical Arbitrary Lagrangian Eulerian (ALE) model was established to simulate orthogonal cutting AISI 52100 bearing steel, and its temperature and stress distribution. Based on ABAQUS, The ALE approach effectively simulates plastic flow around round edge of the cutting tool without employing chip separation criteria. The calculation results reveal that cutting speed and cutting depth have great impact on chip morphology, stress and temperature distribution in the finished surface and subsurface, the predicted temperature agrees well with experiment data obtained under the similar cutting conditions as well as the change in chip morphology from continuous to sawtooth as the cutting speed increases.

Study of the Effect of Tool Wear on Cutting Ti6Al4V Process

2013 ◽  
Vol 690-693 ◽  
pp. 2030-2035
Author(s):  
Shu Bao Yang ◽  
Hong Chao Ni ◽  
Guo Hui Zhu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Key Factors ◽  
Serrated Chip ◽  
Comprehensive Properties ◽  
Commercial Applications ◽  
On Chip ◽  
Rapid Tool

Ti6Al4V alloy is widely used in the aircraft industry, marine and the commercial applications due to its excellent comprehensive properties. However, its poor machinability prevents it from application widely, and the rapid tool wear is one of the key factors. The FEM models of cutting titanium alloy are established. The effect of tool wear on chip morphology, cutting temperature and cutting force are studied. The simulation results show that: the cutting force and cutting temperature will rise with the increase of tool wear. Furthermore, the degree of chip deformation will improve, but the frequency of serrated chip tooth occurred will decrease.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

scholarly journals Fractal Characteristics of Chip Morphology and Tool Wear in High-Speed Turning of Iron-Based Super Alloy

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 1020
Author(s):  
Xu Zhang ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Rufeng Xu ◽  
Guoyong Zhao ◽  
...  
Keyword(s):  
Fractal Dimension ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
Fractal Dimensions ◽  
Chip Morphology ◽  
Color Changes ◽  
Fractal Characteristics ◽  
Iron Based ◽  
Super Alloy

Considering that iron-based super alloy is a kind of difficult-to-cut material, it is easy to produce work hardening and serious tool wear during machining. Therefore, this work aims to explore the chip change characteristics and tool wear mechanism during the processing of iron-based super alloy, calculate the fractal dimensions of chip morphology and tool wear morphology, and use fractals to analyze their change trend. Meanwhile, a new cutting tool with a super ZX coating is used for a high-speed dry turning experiment. The results indicate that the morphology of the chip is saw-tooth, and its color changes gradually, due to the oxidation reaction. The main wear mechanisms of the tool involve abrasive wear, adhesive wear, oxidation wear, coating spalling, microcracking and chipping. The fractal dimension of the tool wear surface and chip is increased with the improvement of cutting speed. This work investigates the fractal characteristics of chip morphology and tool wear morphology. The fractal dimension changes regularly with the change of tool wear, which plays an important role in predicting this tool wear. It is also provides some guidance for the efficient processing of an iron-based super alloy.

Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 1: Effect of gradual tool wear evolution

2015 ◽  
Vol 231 (9) ◽  
pp. 1559-1574 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machined Surface ◽  
Segmented Chip ◽  
Gradual Development ◽  
Geometric Variables ◽  
On Chip

Geometric features of the segmented chip have been investigated along with the volume of material removed at a cutting speed at which tool wear is characterized by the gradual development of flank wear when cutting Ti-6Al-4V alloy. The chip geometric variables varied with an increase in the volume of material removed as the combined effect of change in tool’s geometry and increase in cutting temperature. Plastic deformation dimples were observed as periodical regions on the machined surface, a row on each undeformed surface and region on the top of the slipping surface of the segmented chip when cutting with new tool; these dimples on the undeformed surface and machined surface are elongated in the direction of chip flow. All these dimples became less with an increase in the volume of material removed and almost disappeared when the chip was removed with the worn tool at the end of its life. A model of segmented chip formation process has been proposed to satisfactorily explain the formation of the plastic deformation dimples on the undeformed surface and machined surface of the segmented chip produced with a new cutting tool and the transition of chip geometry with the evolution of tool wear.

Microscale Drilling of Bulk Metallic Glass

2013 ◽  
Vol 1 (4) ◽  
Author(s):  
James Zhu ◽  
Hyun Jin Kim ◽  
Shiv G. Kapoor
Keyword(s):  
Metallic Glass ◽  
Tool Wear ◽  
Bulk Metallic Glass ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Acoustic Emissions ◽  
Chip Morphology ◽  
High Rate ◽  
Burr Height ◽  
Drilling Performance

The microscale drilling performance of a Zr-based bulk metallic glass (BMG) is investigated in this paper. Crystallization, drill temperature, axial force, spindle load (SL), acoustic emissions (AE), chip morphology, hole diameter, and entry burr height are measured and analyzed with varying cutting speed and chip load. The progression of tool wear is assessed using stereo-microscopy techniques. At small chip loads, minimum chip thickness (MCT) is observed to shift cutting mechanics from a shear-dominated to a ploughing-dominated regime. Consequently, evidence of drill instability and larger burr height are observed. As drilling temperatures rise above the glass transition temperature, the BMG thermally softens due to the transition to a super-cooled liquid state and begins to exhibit viscous characteristics. In the tool wear study using tungsten carbide microdrills, rake wear is found to dominate compared to flank wear. This is attributed to a combination of a high rate of diffusion wear on the rake face as well as lower abrasion on the flank due to the decreased hardness from thermal softening-induced viscous flow of BMG.

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