Reprint of “A study of CVD diamond deposition on cemented carbide ball-end milling tools with high cobalt content using amorphous ceramic interlayers”

Ball-end milling of Cr12MoV die steel was studied using ceramic and cemented carbide inserts under different cutting conditions. The cutting forces, wear patterns and chip patterns generated using the different cutting tools at the different cutting conditions were investigated using a three component piezoelectric dynamometer and VHX-600E large depth-of-view 3-D scanner. The relationships among the cutting forces, wear patterns and chip patterns were discussed. The results indicated that the cutting forces caused by the ceramic insert were slightly lower than those caused by the cemented carbide insert under the same cutting conditions. For ceramic inserts, effects of cutting conditions on the rake face wear were different from those on the flank wear. The higher wear for the ceramic insert was caused at the lower cutting conditions but the higher wear for the cemented carbide insert was encountered at the higher cutting conditions. The squeezed chip was involved with the higher cutting forces. The sharper cutting edge of the cemented carbide insert was responsible for chip patterns caused by the No. I cutting condition. The effects of cutting conditions on wear patterns were more evident than that on chip patterns.

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Hydrogen embrittlement of titanium during microwave plasma assisted CVD diamond deposition

Surface Engineering ◽

10.1179/026708400101517251 ◽

2000 ◽

Vol 16 (4) ◽

pp. 355-360 ◽

Cited By ~ 5

Author(s):

Y. Fu ◽

B. Yan ◽

N.L. Loh ◽

C.Q. Sun ◽

P. Hing

Keyword(s):

Hydrogen Embrittlement ◽

Microwave Plasma ◽

Cvd Diamond ◽

Diamond Deposition

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Roughing Milling with Ceramic Tools in Comparison with Sintered Carbide on Nickel-Based Alloys

Coatings ◽

10.3390/coatings11060734 ◽

2021 ◽

Vol 11 (6) ◽

pp. 734

Author(s):

Pablo Fernández-Lucio ◽

Octavio Pereira Neto ◽

Gaizka Gómez-Escudero ◽

Francisco Javier Amigo Fuertes ◽

Asier Fernández Valdivielso ◽

...

Keyword(s):

Cutting Speed ◽

High Volume ◽

Cemented Carbide ◽

Performance Ratio ◽

Cost Performance ◽

Ceramic Tools ◽

The Cost ◽

Engine Components ◽

Coated Carbide ◽

Milling Tools

Productivity in the manufacture of aircrafts components, especially engine components, must increase along with more sustainable conditions. Regarding machining, a solution is proposed to increase the cutting speed, but engines are made with very difficult-to-cut alloys. In this work, a comparison between two cutting tool materials, namely (a) cemented carbide and (b) SiAlON ceramics, for milling rough operations in Inconel® 718 in aged condition was carried out. Furthermore, both the influence of coatings in cemented carbide milling tools and the cutting speed in the ceramic tools were analysed. All tools were tested until the end of their useful life. The cost performance ratio was used to compare the productivity of the tested tools. Despite the results showing higher durability of the coated carbide tool, the ceramic tools presented a better behavior in terms of productivity at higher speed. Therefore, ceramic tools should be used for higher productivity demands, while coated carbide tools for low speed-high volume material removal.

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Study on chip removal mechanism of PCD ball-end milling (1st report) cutting simulation by orthogonal cutting

Production & Manufacturing Research ◽

10.1080/21693277.2020.1862721 ◽

2020 ◽

Vol 8 (1) ◽

pp. 486-495

Author(s):

Peerapong Kasuriya ◽

Takeshi Watanabe ◽

Takashi Goto ◽

Masahiko Jin

Keyword(s):

End Milling ◽

Orthogonal Cutting ◽

Removal Mechanism ◽

Cutting Simulation ◽

Ball End Milling ◽

On Chip ◽

Chip Removal

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Multilayer Diamond Coatings Applied to Micro-End-Milling of Cemented Carbide

Materials ◽

10.3390/ma14123333 ◽

2021 ◽

Vol 14 (12) ◽

pp. 3333

Author(s):

Eduardo L. Silva ◽

Sérgio Pratas ◽

Miguel A. Neto ◽

Cristina M. Fernandes ◽

Daniel Figueiredo ◽

...

Keyword(s):

Electron Microscopy ◽

End Milling ◽

Interfacial Stress ◽

Cemented Carbide ◽

Air Cooling ◽

Micro Machining ◽

Diamond Coatings ◽

Wear Properties ◽

High Adhesion ◽

Micro End Milling

Cobalt-cemented carbide micro-end mills were coated with diamond grown by chemical vapor deposition (CVD), with the purpose of micro-machining cemented carbides. The diamond coatings were designed with a multilayer architecture, alternating between sub-microcrystalline and nanocrystalline diamond layers. The structure of the coatings was studied by transmission electron microscopy. High adhesion to the chemically pre-treated WC-7Co tool substrates was observed by Rockwell C indentation, with the diamond coatings withstanding a critical load of 1250 N. The coated tools were tested for micro-end-milling of WC-15Co under air-cooling conditions, being able to cut more than 6500 m over a period of 120 min, after which a flank wear of 47.8 μm was attained. The machining performance and wear behavior of the micro-cutters was studied by scanning electron microscopy and energy-dispersive X-ray spectroscopy. Crystallographic analysis through cross-sectional selected area electron diffraction patterns, along with characterization in dark-field and HRTEM modes, provided a possible correlation between interfacial stress relaxation and wear properties of the coatings. Overall, this work demonstrates that high adhesion of diamond coatings can be achieved by proper combination of chemical attack and coating architecture. By preventing catastrophic delamination, multilayer CVD diamond coatings are central towards the enhancement of the wear properties and mechanical robustness of carbide tools used for micro-machining of ultra-hard materials.

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Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

Journal for Manufacturing Science and Production ◽

10.1515/jmsp-2014-0055 ◽

2015 ◽

Vol 15 (3) ◽

pp. 293-300 ◽

Cited By ~ 1

Author(s):

Nandkumar N. Bhopale ◽

Nilesh Nikam ◽

Raju S. Pawade

Keyword(s):

Surface Roughness ◽

Response Surface Methodology ◽

Response Surface ◽

Surface Integrity ◽

Inconel 718 ◽

Tool Path ◽

End Milling ◽

Spindle Speed ◽

Depth Of Cut ◽

Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

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Mechanistic Modeling of the Ball End Milling Process for Multi-Axis Machining of Free-Form Surfaces

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1369357 ◽

2000 ◽

Vol 123 (3) ◽

pp. 369-379 ◽

Cited By ~ 85

Author(s):

Rixin Zhu ◽

Shiv G. Kapoor ◽

Richard E. DeVor

Keyword(s):

End Milling ◽

Chip Thickness ◽

Mechanistic Modeling ◽

Free Form ◽

Surface Geometry ◽

Workpiece Surface ◽

Ball End Milling ◽

Modeling Approach ◽

Free Form Surfaces ◽

Cutting Point

A mechanistic modeling approach to predicting cutting forces is developed for multi-axis ball end milling of free-form surfaces. The workpiece surface is represented by discretized point vectors. The modeling approach employs the cutting edge profile in either analytical or measured form. The engaged cut geometry is determined by classification of the elemental cutting point positions with respect to the workpiece surface. The chip load model determines the undeformed chip thickness distribution along the cutting edges with consideration of various process faults. Given a 5-axis tool path in a cutter location file, shape driving profiles are generated and piecewise ruled surfaces are used to construct the tool swept envelope. The tool swept envelope is then used to update the workpiece surface geometry employing the Z-map method. A series of 3-axis and 5-axis surface machining tests on Ti6A14V were conducted to validate the model. The model shows good computational efficiency, and the force predictions are found in good agreement with the measured data.

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