Study on roughness and form errors linked with tool wear in the drilling process of an Al-Si alloy under high cutting speed using coated diamond-like carbon high-speed steel drill bits

2021 ◽  
Vol 62 ◽  
pp. 711-719
Author(s):  
Paulo Sérgio Martins ◽  
José Rubens Gonçalves Carneiro ◽  
Elhadji Cheikh Talibouya Ba ◽  
Vitor Ferreira Vieira
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Diamond Like Carbon ◽  
Drilling Process ◽  
Form Errors ◽  
High Cutting Speed ◽  
Drill Bits ◽  
Steel Drill

Determination of tool wear and chip formation in drilling process of AISI 1045 material using plasma-nitrided high-speed steel drill bits

2015 ◽  
Vol 231 (10) ◽  
pp. 1725-1734 ◽  
Author(s):  
İsmail Ucun ◽  
Serdar Kaplan
Keyword(s):  
Mechanical Properties ◽  
Tool Wear ◽  
Chip Formation ◽  
High Speed ◽  
Plasma Nitriding ◽  
High Speed Steel ◽  
Drilling Process ◽  
Drill Bits ◽  
Aisi 1045 ◽  
Steel Drill

In this study, tool wear and chip formation during the drilling process of AISI 1045 material using plasma-nitrided high-speed steel drill bits were experimentally investigated. Two uncoated and plasma-nitrided drill types were used in the experiments. First, commercial drill bits were subjected to the plasma nitriding process. Following this, the drilling processes were carried out at various feed rates and cutting speeds. A sensitive computer numerical control machine was used in the experiments. Tool wear was determined using scanning electron microscopy and chips obtained from the drilling process were observed under microscopy. Finally, the relationship between the chip cross section and tool wear was determined using statistical analysis. It was concluded that the mechanical properties of uncoated high-speed steel drill bits improve significantly through the plasma nitriding process. Less tool wear and a good chip formation were observed with the improvement of the mechanical properties. It was determined that there is a relationship between the chip section and wear.

Experimental Analysis of Wear Mechanism and Tool Life in Dry Drilling of Al2024

2012 ◽  
Vol 566 ◽  
pp. 217-221 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Raja Ishak Raja Hamzah ◽  
Abdolkarim Niazi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dry Machining ◽  
Hole Quality ◽  
High Cutting Speed

Aluminum alloy is widely used in industry and various researches has been done on machiability of this material mainly due to its low weight and other superior properties. Dry machining is still interesting topic to reduce the cost of manufacturing and environmental contaminations. In present study dry machining of Al 2024 investigated on tool life, tool wear mechanisms, hole quality, thrust force and torque. Different types of high speed steel (HSS) tools utilized at constant feed rate of 0.04 mm/rev and cutting speeds within the range of 28 and 94 m/min. Experimental results revealed that HSCo drills, performed better than HSS drills in terms of tool life and hole quality. The main wear mechanisms which analyzed by scanning electron microscope found abrasive and adhesion wear on flank face, besides, BUE observed at chisel and cutting edges. However tool wear and BUE formation found more significant at high cutting speed. In terms of thrust force, two facet HSCo tools, recorded higher thrust force than four facet HSS drills.

Wear Characteristics of Twist Drills in Machining Fluorophlogopite

2007 ◽  
Vol 336-338 ◽  
pp. 1465-1468
Author(s):  
L.J. Ma ◽  
Ai Bing Yu ◽  
Z.M. Mei
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Cooling Condition ◽  
Machining Parameters ◽  
Tool Materials ◽  
Drill Bits ◽  
Steel Drill ◽  
Fluorophlogopite Ceramics

The machinable fluorophlogopite was drilled with tungsten-cobalt carbide and high-speed steel drill bits, respectively. The wear widths of major flank were measured, and the wear characteristic of twist was analyzed during drilling fluorophlogopite ceramics.Drilling experiments were carried to consider influence factors of drill bit wear, such as tool materials, cooling condition, spindle speed and tool angles. Tool materials and cooling conditions are the major factors to affect wear of drill bits. High-speed steel drill bits are not suitable for drilling fluorophlogopite ceramics. Cooling condition affects wear remarkably. With the rising of spindle speed, the wear widths of major flank grows. But apex angle has little affects on the tool wear rate. Research results indicate that low tool wear can be obtain through optimizing tool material and machining parameters in drilling fluorophlogopite ceramics.

scholarly journals An experimental investigation of the effects of point angle on the high-speed steel drills performance in drilling

2018 ◽  
Vol 51 (9-10) ◽  
pp. 417-430 ◽  
Author(s):  
Zülküf Demir
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Cutting Edge ◽  
Drilling Process ◽  
Cutting Speeds

The differences in the cutting speed are a serious problem along the cutting edge of the drill, in drilling operations. This problem can partly be solved reducing the length of the cutting edge via changing the drill point angle. In addition, in this study, the effect of point angle, feed rate, and cutting speed on drilling is investigated. For identifying the optimum cutting parameters, AISI 1050 steel alloy was selected as the experimental specimen, these specimen were pre-drilled 5 mm in diameter due to eliminating the effect of the chisel edge. In the experiments, the holes were drilled only at a depth of 10 mm in order not to give any harm to the dynamometer while measuring thrust force. For this aim, in drilling process, drills with point angle of 100°, 118°, 136°, 154°, and 172° were selected. In conclusion, the thrust force, the tool wear, and the surface roughness linearly decreased with increasing point angles due to less removal chip area, in per revolve of the tool. However, the thrust force, the tool wear, and the surface roughness were adversely affected at higher feed rates and lower cutting speeds. The hole dimensional accuracy decreased at lower feed rates and cutting speeds but at higher point angles and concurrently at higher feed rates but lower point angles and cutting speeds. However, the hole dimensional accuracy showed more decisiveness at 118° than other point angles, while the highest dimensional accuracy values recorded at 136° point angle, at higher cutting speeds.

Feasibility Study of the Effectiveness of Cryogenically Treated Ceramic Inserts for Pocket Milling Maneuvers

2009 ◽  
Author(s):  
Justin L. Milner ◽  
Jeffrey A. Beers ◽  
John T. Roth
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Feasibility Study ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Initial Study ◽  
Machining Processes ◽  
Cutting Speeds

Machining is a popular and versatile manufacturing process that is widely used in today’s industry when producing metallic parts; however, limited tool life can make this an expensive and time consuming fabrication technique. Consequently, methods that decrease the rate of tool wear and, thus, increase tool longevity are a vital component when improving the efficiency of machining processes. To this end, cryogenically treating cutting tools (especially high-speed steel tooling) is becoming more commonplace since research has shown that the treated tooling exhibits significantly higher wear resistance. At this point, however, the effect of cryogenic treatments on ceramic tooling has not been established. Considering this, the research herein presents a feasibility study on the effectiveness of using cryogenic treatments to enhance the wear resistance of WG-300 whisker-reinforced ceramic cutting inserts. To begin, the effect of the cryogenic treatment on the insert’s hardness is examined. Subsequently, tool wear tests are conducted at various cutting speeds. Through this study, it is shown that cryogenically treating the ceramic inserts decreases the rate of tool wear at each of the cutting speeds that were tested. However, the degree of wear resistance introduced by cryogenically treating the inserts proved to be highly dependent on the cutting speed, with slower speeds exhibiting greater improvements. Thus, based on this initial study, the cryogenic treatment of ceramic tooling appears to produce beneficial results, potentially increasing the overall efficiency of machining processes.

On-Line Monitoring of Drill Wear Using Air-Coupled Audio Microphone when Drilling Composite Materials

2014 ◽  
Vol 590 ◽  
pp. 645-650 ◽  
Author(s):  
Eshetu D. Eneyew ◽  
Mamidala Ramulu
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Flank Wear ◽  
High Speed Steel ◽  
High Rate ◽  
Drilling Process ◽  
Monitoring Method ◽  
On Line

The condition of the cutting tool when drilling composite materials is the controlling factor for the surface integrity of hole produced. The high rate of tool wear when drilling composite materials makes finding a way to monitor the condition of the cutting tool without interrupting the drilling process a great necessity. Inspecting the condition of the drill between or during the drilling process is not practical or economical. In an attempt to tackle this problem, a new approach of on-line tool wear monitoring method using an air-coupled audio microphone is proposed. An experimental investigation was conducted on multi-directional carbon fiber reinforced plastic (CFRP) composite material using a high speed steel (HSS) drill. The result shows that, the amplitude of the acoustic signal from the microphone decreases when the amount of flank wear increases and the amplitude of thrust force and torque increases with the increase of the flank wear. This result demonstrates that the proposed approach can be used as an effective and economical tool for on-line monitoring of cutting tool condition.

scholarly journals The influence of drill point geometry on tool life

2018 ◽  
Vol 12 (1) ◽  
pp. 1-4 ◽  
Author(s):  
Zlatko Botak ◽  
Marko Horvat
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
High Speed Steel ◽  
Solid Material ◽  
Processing Parameters ◽  
Drill Bit ◽  
Drill Bits ◽  
Steel Drill ◽  
Drill Point ◽  
Efficiency Comparison

Drilling is a cutting process that uses a rotary cutting tool to cut a cylindrical hole in a solid material. During machining, drill bits are exposed to rapid wear at high temperature. Sometimes, due to an ecological need for dry technology without any lubricant, the use of drill bits with coatings is required, typically titanium nitride (TiN), titanium carbon nitride (TiCN) or titanium aluminium nitride (TiAlN). This paper presents research on drilling done to determine how drill point geometry affects the drill lifetime and finished surface quality. We compared the chip removal ability and surface quality of bored holes in Hardox 500 created with high-speed steel drill bits and drill bits manufactured from hard metals, with and without coatings, under constant processing parameters. A cost/efficiency comparison was also carried out with respect to drill bit fabrication, sharpening, and use. Based on the data obtained on the damage drill points, the most economical drill bit for processing holes was determined.

Tool Wear of Diamond-Like Carbon-Coated High-Speed Steel with a Cr-Based Interlayer in Cutting of Aluminum Alloys

2012 ◽  
Vol 152-154 ◽  
pp. 74-79
Author(s):  
Tadahiro Wada ◽  
Koji Iwamoto ◽  
Hiroaki Sugita
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Diamond Like Carbon ◽  
Aluminum Alloy 6061 ◽  
Coated Tool ◽  
Alloy 6061

In cutting aluminum alloy 6061, continuous chips have a negative influence on the machining operation. Usually, Pb is added in order to break continuous chips. However, from the standpoint of environmental protection, it is necessary to improve chip breakability without adding Pb. One effective measure to improve chip breakability is by adding Si to aluminum alloy 6061. However, the influence of Si content on tool wear has not been fully examined. In this study, in order to clarify the influence of a diamond-like carbon (DLC) coating layer with a Cr-based interlayer, namely (Al,Cr)N, on cutting performance, aluminum alloys having different Si contents were turned. The substrate of the tool material was high-speed steel (1.4%C). The tool wear and the surface roughness were experimentally investigated. The following results were obtained: (1) In cutting two kinds of Al-Si alloys, namely the Al-2%Si alloy and Al-4%Si alloy, the progress of wear of the DLC/(Al,Cr)N-coated tool was slower than that of the DLC-coated tool. Therefore, the (Al,Cr)N interlayer was effective for decreasing the tool wear of the DLC-coated tool. (2) The wear progress of the two kinds of DLC-coated tools in cutting of Al-4%Si alloy was faster than that in cutting of Al-2%Si alloy. (3) In cutting of Al-2%Si alloy with the (Al,Cr)N/DLC-coated tool, the surface roughness was almost constant in the range of a cutting distance from 0.1 km to 9.5 km.

Effect of Cryogenic Minimum Quantity Lubrication (CMQL) on Cutting Temperature and Tool Wear in High-Speed End Milling of Titanium Alloys

2010 ◽  
Vol 34-35 ◽  
pp. 1816-1821 ◽  
Author(s):  
Yu Su ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
High Speed ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
High Cutting Speed ◽  
Cryogenic Minimum Quantity Lubrication

Cryogenic minimum quantity lubrication (CMQL) is a kind of green cooling/lubrication technique, which consists of the application of a small amount of lubricant (6-100 ml/h), delivered in a refrigerated compressed gas stream to the cutting zone. This paper experimentally investigates the effect of CMQL on cutting temperature and tool wear in high-speed end milling of titanium alloys. Comparative experiments were conducted under different cooling/lubrication conditions, i.e. dry milling, refrigerated air cutting, and CMQL. The refrigerated gas equipment was manufactured based on composite refrigeration method to provide the refrigerated air. The experimental results show that application of CMQL resulted in drastic reduction in cutting temperature and tool wear especially when machining titanium alloys at a high cutting speed.

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