Experimental Investigation of Tool Wear Behavior of Multi-Layered Coated Carbide Inserts Using Various Sensors in Hard Turning Process

Tool wear phenomena during the machining of titanium alloys are very complex. Severe adhesive interaction at the tool chip interface, especially at low cutting speeds, leads to intensive Built Up Edge (BUE) formation. Additionally, a high cutting temperature causes rapid wear in the carbide inserts due to the low thermal conductivity of titanium alloys. The current research studies the effect of AlTiN and CrN PVD coatings deposited on cutting tools during the rough turning of a Ti6Al4V alloy with severe BUE formation. Tool wear characteristics were evaluated in detail using a Scanning Electron Microscope (SEM) and volumetric wear measurements. Chip morphology analysis was conducted to assess the in situ tribological performance of the coatings. A high temperature–heavy load tribometer that mimics machining conditions was used to analyze the frictional behavior of the coatings. The micromechanical properties of the coatings were also investigated to gain a better understanding of the coating performance. It was demonstrated that the CrN coating possess unique micromechanical properties and tribological adaptive characteristics that minimize BUE formation and significantly improve tool performance during the machining of the Ti6Al4V alloy.

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Experimental Investigation into Wear and Tool Life of Milling Cutter PVD Coated Carbide Inserts While Armox 500 Steel Hard Milling

Tehnicki vjesnik - Technical Gazette ◽

10.17559/tv-20161128094553 ◽

2018 ◽

Vol 25 (6) ◽

Keyword(s):

Experimental Investigation ◽

Tool Life ◽

Hard Milling ◽

Milling Cutter ◽

Coated Carbide ◽

Carbide Inserts

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Artificial neural network based tool wear estimation on dry hard turning processes of AISI4140 steel using coated carbide tool

Bulletin of the Polish Academy of Sciences Technical Sciences ◽

10.1515/bpasts-2017-0060 ◽

2017 ◽

Vol 65 (4) ◽

pp. 553-559 ◽

Cited By ~ 1

Author(s):

D. Rajeev ◽

D. Dinakaran ◽

S.C.E. Singh

Keyword(s):

Neural Network ◽

Artificial Neural Network ◽

Tool Wear ◽

Hard Turning ◽

Cutting Tool ◽

Carbide Tool ◽

Online Tool ◽

Coated Carbide Tool ◽

Tool Wear Estimation ◽

Coated Carbide

AbstractNowadays, finishing operation in hardened steel parts which have wide industrial applications is done by hard turning. Cubic boron nitride (CBN) inserts, which are expensive, are used for hard turning. The cheaper coated carbide tool is seen as a substitute for CBN inserts in the hardness range (45–55 HRC). However, tool wear in a coated carbide tool during hard turning is a significant factor that influences the tolerance of machined surface. An online tool wear estimation system is essential for maintaining the surface quality and minimizing the manufacturing cost. In this investigation, the cutting tool wear estimation using artificial neural network (ANN) is proposed. AISI4140 steel hardened to 47 HRC is used as a work piece and a coated carbide tool is the cutting tool. Experimentation is based on full factorial design (FFD) as per design of experiments. The variations in cutting forces and vibrations are measured during the experimentation. Based on the process parameters and measured parameters an ANN-based tool wear estimator is developed. The wear outputs from the ANN model are then tested. It was observed that as the model using ANN provided quite satisfactory results, and that it can be used for online tool wear estimation.

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Performance Evaluation of MQL Parameters Using Al2O3 and MoS2 Nanofluids in Hard Turning 90CrSi Steel

Lubricants ◽

10.3390/lubricants7050040 ◽

2019 ◽

Vol 7 (5) ◽

pp. 40 ◽

Cited By ~ 14

Author(s):

Tran Minh Duc ◽

Tran The Long ◽

Tran Quyet Chien

Keyword(s):

Hard Turning ◽

Cutting Performance ◽

Hard Machining ◽

High Productivity ◽

Good Surface ◽

Complex Part ◽

Cutting Zone ◽

Grinding Operations ◽

Coated Carbide ◽

Carbide Inserts

Hard machining has gained much attention to be an alternative solution for many traditional finish grinding operations due to high productivity, ease to adapt to complex part contours, the elimination of cutting fluids, good surface quality, and the reduction of machine tool investment. However, the enormous amount of heat generated from the cutting zone always requires the high-grade inserts and limits the cutting conditions. The MQL technique with nanofluids assisted for hard machining helps to improve the cutting performance while ensuring environmentally friendly characteristics. This paper focuses on the development of MQL technique by adding Al2O3 and MoS2 nanoparticles to the base fluids (soybean oil and water-based emulsion) for the hard turning of 90CrSi steel (60÷62 HRC). The analysis of variance (ANOVA) is used to evaluate the performance of MQL parameters in terms of cutting forces and surface roughness. The study reveals that a better performance of coated carbide inserts is observed by using MQL with Al2O3 and MoS2 nanofluids. In addition, the fluid type, nanoparticles and nanoparticle concentration have a strong effect on cutting performance. The interaction influence among the investigated variables is also studied in order to provide the technical guides for further studies using Al2O3 and MoS2 nanofluids.

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Performance comparison of coated carbide tool under different cooling/lubrication environments during face milling of Inconel-625 and Stainless Steel 304

World Journal of Engineering ◽

10.1108/wje-06-2018-0194 ◽

2019 ◽

Vol 16 (2) ◽

pp. 287-295 ◽

Cited By ~ 1

Author(s):

Pragat Singh ◽

J.S. Dureja ◽

Harwinder Singh ◽

Manpreet S. Bhatti

Keyword(s):

Tool Wear ◽

Wear Behavior ◽

Face Milling ◽

Cutting Fluid ◽

Inconel 625 ◽

Machining Performance ◽

Content Type ◽

Stainless Steel 304 ◽

Coated Carbide ◽

Ss 304

PurposeThis study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).Design/methodology/approachMachining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.FindingsThe results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.Research limitations/implicationsInconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.Originality/valueThe literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

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An experimental investigation for the improvement of attainable surface roughness during hard turning process

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405412464217 ◽

2013 ◽

Vol 227 (2) ◽

pp. 338-342 ◽

Cited By ~ 23

Author(s):

Waleed B Rashid ◽

Saurav Goel ◽

Xichun Luo ◽

James M Ritchie

Keyword(s):

Surface Roughness ◽

Experimental Investigation ◽

Hard Turning ◽

Turning Process

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Influence of the cutting edge preparation method on characteristics and performance of PVD coated carbide inserts in hard turning

Surface and Coatings Technology ◽

10.1016/j.surfcoat.2014.07.003 ◽

2014 ◽

Vol 254 ◽

pp. 447-454 ◽

Cited By ~ 16

Author(s):

B. Denkena ◽

J. Köhler ◽

B. Breidenstein ◽

A.M. Abrão ◽

C.E.H. Ventura

Keyword(s):

Hard Turning ◽

Preparation Method ◽

Cutting Edge ◽

Cutting Edge Preparation ◽

And Performance ◽

Coated Carbide ◽

Carbide Inserts ◽

Edge Preparation

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Tool wear and machining performance of cBN–TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2006.06.013 ◽

2006 ◽

Vol 180 (1-3) ◽

pp. 253-262 ◽

Cited By ~ 114

Author(s):

Abhijeet S. More ◽

Wenping Jiang ◽

W.D. Brown ◽

Ajay P. Malshe

Keyword(s):

Tool Wear ◽

Hardened Steel ◽

Machining Performance ◽

Coated Carbide ◽

Carbide Inserts ◽

Aisi 4340

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Tool Wear Behavior in Turning Inconel 718 with Coated Inserts

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.499.348 ◽

2012 ◽

Vol 499 ◽

pp. 348-352 ◽

Cited By ~ 1

Author(s):

Xiao Li Zhu ◽

Song Zhang ◽

X.L. Xu ◽

H.G. Lv

Keyword(s):

Tool Wear ◽

Inconel 718 ◽

Flank Wear ◽

Wear Behavior ◽

Cutting Tools ◽

Three Dimensional ◽

Cutting Condition ◽

Tool Holder ◽

Final Failure ◽

Coated Carbide

In the present study, an experimental investigation has been carried out in an attempt to monitor tool wear progress in turning Inconel 718 with coated carbide inserts under the wet cutting condition. First, each experimental test was conducted with a new cutting edge and the turning process was stopped at a certain interval of time. Secondly, the indexable insert was removed from the tool holder and the flank wear of the insert was measured using a three-dimensional digital microscopy (VHX-600E); and then the insert was clamped into the tool holder for the next turning experiment. The final failure of tool wear surfaces were examined under a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectrometer (EDS). It is indicated that significant flank wear was the predominant failure mode, and the abrasive, adhesive and oxidation wear were the most dominant wear mechanisms which directly control the deterioration and final failure of the cutting tools.

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