Influences of coating thickness on cutting temperature for dry hard turning Inconel 718 with PVD TiAlN coated carbide tools in initial tool wear stage

2020 ◽  
Vol 56 ◽  
pp. 1155-1165 ◽  
Author(s):  
Jinfu Zhao ◽  
Zhanqiang Liu
Keyword(s):  
Tool Wear ◽  
Coating Thickness ◽  
Inconel 718 ◽  
Hard Turning ◽  
Cutting Temperature ◽  
Coated Carbide ◽  
Coated Carbide Tools

Comparative Assessment of Coated CBN and Multilayer Coated Carbide Tools on Tool Wear in Hard Turning AISID2 Steel

2018 ◽  
Author(s):  
M.Junaid Mir ◽  
M.F. Wani ◽  
Summera Banday ◽  
Shuhaib Mushtaq ◽  
Jebran Khan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Comparative Assessment ◽  
Coated Carbide ◽  
Coated Carbide Tools

scholarly journals EFFECT OF HIGH PRESSURE COOLANT JET ON CUTTING TEMPERATURE, TOOL WEAR AND SURFACE FINISH IN TURNING HARDENED (HRC 48) STEEL

2015 ◽  
Vol 45 (1) ◽  
pp. 1-6 ◽  
Author(s):  
Mozammel Mia ◽  
Nikhil Ranjan Dhar
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Cutting Forces ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Beneficial Effects ◽  
Coated Carbide ◽  
High Pressure Coolant

Hard turning of harder material differs from conventional turning because of its larger specific cutting forces requirements. The beneficial effects of hard turning can be offset by excessive temperature generation which causes rapid tool wear or premature tool failure if the brittle cutting tools required for hard turning are not used properly. Under these considerations, the concept of high-pressure coolant (HPC) presents itself as a possible solution for high speed machining in achieving slow tool wear while maintaining cutting forces at reasonable levels, if the high pressure cooling parameters can be strategically tuned. This paper deals with an experimental investigation of some aspects of the turning process applied on hardened steel (HRC48) using coated carbide tool under high-pressure coolant, comparing it with dry cut. The results indicate that the use of high-pressure coolant leads to reduced surface roughness, delayed tool flank wear, and lower cutting temperature, while also having a minimal effect on the cutting forces.

Research on Cutting Performance of High-Speed Steel Drills during Drilling the Powder Metallurgy Nickel-Based Superalloy

2011 ◽  
Vol 464 ◽  
pp. 556-559 ◽  
Author(s):  
Yang Qiao ◽  
Xing Ai ◽  
Zhan Qiang Liu
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
High Speed ◽  
Research Work ◽  
Cutting Temperature ◽  
High Speed Steel ◽  
Machining Parameters ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

The present paper is an experimental investigation on the machinability of powder metallurgy (PM) nickel-based superalloy during drilling using high-speed steel (M42) drills. The effect of machining parameters on the cutting force, cutting temperature and tool wear were investigated during the experimentation. The effect of machining parameters on the tool wear was examined through SEM micrographs. The research work findings will also provide useful economic machining solution by utilizing economical high-speed steel drills during drilling processing of powder metallurgy nickel-based superalloy, which is otherwise usually machined by costly coated carbide tools or CBN tools. The present approach and results will be helpful for understanding the machinability of powder metallurgy nickel-based superalloy during drilling for the manufacturing engineers.

scholarly journals Tool Condition Monitoring in Hard Turning of Inconel 718 by using Vibration Technique

2019 ◽  
Vol 8 (11) ◽  
pp. 1143-1147
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Inconel 718 ◽  
Hard Turning ◽  
High Hardness ◽  
Tool Condition Monitoring ◽  
Depth Of Cut ◽  
Vibration Signals ◽  
Tool Condition ◽  
Coated Carbide

In various machining processes, the vibration signals are studied for tool condition monitoring often referred as wear monitoring. It is essential to overcome unpredicted machining trouble and to improvise the efficiency of the machine. Tool wear is a vital problem in materials such as nickel based alloys as they have high hardness ranges. Though they have high hardness, a nickel based alloy Inconel 718 with varying HRC (51, 53, and 55), is opted as work material for hard turning process in this work. Uncoated and coated carbide tools are employed as cutting tools. Taguchi’s L9 orthogonal array is considered by taking hardness, speed, feed and depth of cut as four input parameters, the number of experiments and the combinations of parameters for every run is obtained. The vibration signals are recorded at various stages of cutting, till the tool failure is observed. Taking this vibration signal data as input to ANOVA and Grey relation analysis (GRA) which categorizes the optimal and utmost dominant features such as Root Mean Square (RMS), Crest Factor (CF), Skewness (Sk), Kurtosis (Ku), Absolute Deviation (AD), Mean, Standard Deviation (SD), Variance, peak, Frequency and Time in the tool wear process

scholarly journals Comparision of Dominant Features Identification for Tool Wear in Hard Turning of Inconel 718 by Using Vibration Analysis

2019 ◽  
Vol 69 (4) ◽  
pp. 1-8
Author(s):  
Dasari Kondala Rao ◽  
Kolla Srinivas
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Hard Turning ◽  
High Hardness ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Absolute Deviation ◽  
Vibration Signals ◽  
Wear Process ◽  
Coated Carbide

AbstractIn various machining processes, the vibration signals are studied for tool condition monitoring often referred as wear monitoring. It is essential to overcome unpredicted machining trouble and to improvise the efficiency of the machine. Tool wear is a vital problem in materials such as nickel based alloys as they have high hardness ranges. Though they have high hardness, a nickel based alloy Inconel 718 with varying HRC (51, 53, and 55), is opted as work material for hard turning process in this work. Uncoated carbide, coated carbide and ceramic tools are employed as cutting tools. Taguchi’s L9 orthogonal array is considered by taking hardness, speed, feed and depth of cut as four input parameters, the number of experiments and the combinations of parameters for every run is obtained. The vibration signals are recorded at various stages of cutting, till the tool failure is observed. Taking this vibration signal data as input to ANOVA and Grey relation analysis (GRA) which categorizes the optimal and utmost dominant features such as Root Mean Square (RMS), Crest Factor (CF), Skewness (Sk), Kurtosis (Ku), Absolute Deviation (AD), Mean, Standard Deviation (SD), Variance, peak, Frequency and Time in the tool wear process.

scholarly journals Investigation of the Wear Behavior of PVD Coated Carbide Tools during Ti6Al4V Machining with Intensive Built Up Edge Formation

Coatings ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 266
Author(s):  
M.S.I. Chowdhury ◽  
B. Bose ◽  
S. Rawal ◽  
G.S. Fox-Rabinovich ◽  
S.C. Veldhuis
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Wear Behavior ◽  
Cutting Temperature ◽  
Ti6al4v Alloy ◽  
Adhesive Interaction ◽  
Heavy Load ◽  
Micromechanical Properties ◽  
Rough Turning ◽  
Coated Carbide

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.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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

2017 ◽  
Vol 65 (4) ◽  
pp. 553-559 ◽  
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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