Experimental investigation on tool life and chip morphology in hot machining of Monel-400

2018 ◽  
Vol 21 (3) ◽  
pp. 371-379 ◽  
Author(s):  
Asit Kumar Parida ◽  
Kalipada Maity
Keyword(s):  
Experimental Investigation ◽  
Tool Life ◽  
Chip Morphology ◽  
Hot Machining ◽  
Monel 400

scholarly journals Experimental investigation of various machining attributes and cost estimation during machining of hardened AISI 4340 steel with untreated and cryo treated cermet inserts

2020 ◽  
Vol 21 (1) ◽  
pp. 110 ◽  
Author(s):  
Anshuman Das ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Bibhuti Bhusan Biswal
Keyword(s):  
Experimental Investigation ◽  
Tool Life ◽  
Cost Estimation ◽  
Cryogenic Treatment ◽  
Chip Morphology ◽  
Experimental Result ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Hardened Steels ◽  
The Impact

Now-a-days due to growing demand of high precision components to attain high performances, hardened steels with hardness above 45HRC have numerous applications in automotive gear, machine tool and die industry because of their superior characteristics (high thermal stability, high indentation resistance, high abrasiveness, low ductility and high value of hardness to modulus of elasticity ratio). For this, higher tool life of cutting inserts cryogenic treatment is considered as the most prominent method but no substantial researches have been found concerning the impact of cryogenic treatment on cermet inserts, especially in turning of hardened steels. Therefore, in the present experimental investigation, the comparative assessment of various responses such as cutting force, flank wear, crater wear, chip morphology and surface roughness were carried out during machining of hardened steel with both untreated and cryo-treated cermet inserts under dry cutting condition. Lastly, the input variables were optimized using Response Surface Methodology (RSM) to evaluate the tool life for the economic analysis. The experimental result demonstrated that the uncoated deep cryo-treated with tempered cermet insert delivered better results in comparison to other cermet inserts. According to cost analysis, uncoated and deep cryo-treated with tempered cermet insert was found to be the most cost saving among other cermet inserts at the optimum cutting condition.

Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

Finite Element Analysis of Tool Wear in Hot Machining Process

2019 ◽  
pp. 232-248
Author(s):  
Asit Kumar Parida
Keyword(s):  
Tool Wear ◽  
Room Temperature ◽  
Heating Temperature ◽  
Chip Morphology ◽  
High Hardness ◽  
Tool Temperature ◽  
Element Analysis ◽  
Hot Machining ◽  
Wear And Corrosion Resistance ◽  
Wear Tool

Super alloys have been used widely in all sectors (e.g., automobile, aerospace, biomedical, etc.) for their properties like high hardness, high wear, and corrosion resistance. A central challenge is the significantly higher temperature and pressure on the cutting tool, hence rapid tool wear and bad surface finish. In the present study, a FEM analysis has been developed to calculate the effect of preheating temperature on the surface of the workpiece on tool wear on machining Inconel 718. Usui's tool wear model has been implemented in DEFORM software. In order to validate the results, an experimental investigation has been carried out with same cutting conditions. The evaluated results were also compared with the room temperature machining condition. It was observed that the heating temperature increased the tool life by reducing tool wear, tool temperature compared to room temperature machining condition. The predicted tool wear, tool temperature, and chip morphology have been compared with the experimental results and good correlation was found.

Experimental Investigation to Optimize Tool Life and Surface Roughness in Inconel 718 Machining

2015 ◽  
Vol 31 (13) ◽  
pp. 1683-1691 ◽  
Author(s):  
Farshid Jafarian ◽  
Domenico Umbrello ◽  
Saeid Golpayegani ◽  
Zahra Darake
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Tool Life ◽  
Inconel 718

Theoretical and Experimental Investigation of Machining of AISI H13 Steel

2013 ◽  
Vol 818 ◽  
pp. 187-192
Author(s):  
Takács Márton ◽  
Farkas Balázs Zsolt
Keyword(s):  
Experimental Investigation ◽  
Finite Element ◽  
Cutting Speed ◽  
Chip Morphology ◽  
H13 Steel ◽  
Research Activity ◽  
Workpiece Material ◽  
Aisi H13 ◽  
Cutting Processes ◽  
Chip Removal

Main aim of our recent research activity is the theoretical and experimental investigation of hard turning of AISI H13 (52 HRC) hot work tool steel. Chip removal processes are of essential importance in modern manufacturing technology. The demand for higher accuracy, better surface roughness, more economical production, and miniaturization are constantly growing. This determines continuous research and development of cutting processes under special circumstances. Numerical simulation plays an important role in evaluating of the cutting processes, and in prediction of forces, chip formation, distribution of strain, strain rate, stresses, and temperature. Cutting experiments with varying feed rate and cutting speed were carried out to determine their effect on surface components of resultant force. 3D finite element model was proposed to simulate the chip removal process during turning of workpiece material AISI H13 (52 HRC). This paper gives a summary about the comparison of theoretical and experimental results. It was found that boundary conditions, such as finite element size, mesh density, material separation method has significant influence on chip morphology and value of cutting force, too.

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