PVD multi-coated carbide milling inserts performance: Comparison between cryogenic and dry cutting conditions

2022 ◽  
Vol 73 ◽  
pp. 895-902
Author(s):  
Nurul Hayati Abdul Halim ◽  
Che Hassan Che Haron ◽  
Jaharah Abdul Ghani
Keyword(s):  
Performance Comparison ◽  
Cutting Conditions ◽  
Dry Cutting ◽  
Coated Carbide

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.

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

2011 ◽  
Vol 223 ◽  
pp. 286-295 ◽  
Author(s):  
Cédric Courbon ◽  
Tarek Mabrouki ◽  
Joël Rech ◽  
Denis Mazuyer ◽  
Enrico D'Eramo
Keyword(s):  
Heat Flux ◽  
Hot Spot ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Contact Length ◽  
Dry Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The present work proposes to enhance the thermal interface denition in Finite Element (FE) simulations of machining. A user subroutine has been developed in Abaqus/Explicit © to implement a new experimentally-based heat partition model extracted from tribological tests. A 2D Arbitrary-Lagragian-Eulerian (ALE) approach is employed to simulate dry orthogonal cutting of AISI 1045 steel with coated carbide inserts. Simulation results are compared to experimental ones over a whole range of cutting speeds and feed rates in terms of average cutting forces, chip thickness, tool chip contact length and heat flux. This study emphasizes that heat transfer and temperature distribution in the cutting tool are drastically in uenced by the thermal formulation used at the interface. Consistency of the numerical results such as heat flux transmitted to the tool, peak temperature as well as hot spot location can be denitively improved.

Experimental Study on Turning of Alloy Cast Iron with Coated and Uncoated Tools

2010 ◽  
Vol 135 ◽  
pp. 265-270 ◽  
Author(s):  
Q.C. Wang ◽  
Qing Long An ◽  
Ming Chen ◽  
Gang Liu ◽  
Yun Shan Zhang
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Tool Wear ◽  
Great Influence ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Tool ◽  
Coated Carbide ◽  
Alloy Cast Iron ◽  
Alloy Cast

Alloy cast iron cylinder is the mainstream product used in engine nowadays. However, the machinability of alloy cast iron is poor because of its enhanced mechanical properties. In this paper, turning experiment has been conducted to study machinability of alloy cast iron with uncoated and coated carbide tools under dry cutting condition. The results of the experiment indicated that the turning performance of alloy cast iron with coated tool was much better than uncoated tool in terms of cutting force coefficients and tool wear. Feed rate has a great influence on surface roughness, and appropriate tool wear is benefit of finished surface roughness.

Experimental Study on Nano-TiAlN Coated Carbide Tools in Turning Austenitic Stainless Steel

2012 ◽  
Vol 723 ◽  
pp. 247-251
Author(s):  
Hai Dong Yang ◽  
Zhi Ding
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Dry Cutting ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Austenitic stainless steel has poor cutting performance, especially when the inappropriate choice of tool materials and cutting parameters, cutting tool life will be shortened and the quality of machined surface is poor. In this paper, 0Cr18Ni9 stainless steel dry cutting tests had been done with nano-TiAlN coated carbide blade YGB202, the relationship between tool life and cutting speed, tool wear mechanism had been analyzed. In order to improve the processing efficiency and tool life, process parameters were optimized.

A Study of Cutting Forces in High-Speed Dry Milling of Inconel 718

2012 ◽  
Vol 500 ◽  
pp. 105-110 ◽  
Author(s):  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Yield ◽  
Dry Milling ◽  
Machining Processes ◽  
Dry Cutting ◽  
High Tendency ◽  
Coated Carbide

nconel 718 is one of the most commercially important superalloys but with very poor machinability. It has a very high yield stress and a high tendency to adhesion and work-hardening. A recent trend of improving the machining processes of difficult-to-cut materials is to move towards dry cutting operations. This paper presents an experimental study of the cutting forces in high speed dry milling of Inconel 718 using a milling cutter with coated carbide inserts. It is found that the peak cutting forces increase with an increase in chip load in a nonlinear way, but cutting speed does not show a significant influence on the cutting force for the range of cutting speeds tested in this study.

Effect of Pressure and Nozzle Angle of Minimal Quantity Lubrication on Cutting Temperature and Tool Wear in Turning

2014 ◽  
Vol 695 ◽  
pp. 676-679 ◽  
Author(s):  
Abdullah Yassin ◽  
Chong Yaw Teo
Keyword(s):  
Tool Wear ◽  
Palm Oil ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Manufacturing Cost ◽  
Dry Cutting ◽  
Optimum Cutting ◽  
Minimal Quantity Lubrication ◽  
Minimal Quantity

This paper presents an experimental investigation on effects of pressure and nozzle angle of minimal quantity lubrication (MQL) on cutting temperature and flank wear in turning. In manufacturing industries, there are always demands for the optimum cutting conditions for the most economical manufacturing cost. Hence, reduction in tool wear is essential for less expenditure with the knowledge of optimum cutting conditions of MQL. MQL, also known as near dry machining, has been acknowledged as an effective cooling technique in machining by applying vegetable oils in replacing the conventional flooding method due to environmental issues. By varying the operating pressures and nozzle angle with respect to the cutting zone, cutting temperature and flank wear are measured using a calibrated tool work thermocouple and SPG video microscope. Comparison was made between dry cutting, water mist cooling and MQL method with palm oil. Results showed that MQL with palm oil exhibits best cooling efficiency at 5 bar pressure and nozzle angle of 20o with reduction of 35% in tool wear and 23% in cutting temperature at higher cutting speeds.

Acoustic Emission Based Tool Wear Condition Monitoring While Turning Nimonic C-263 Alloy Using PVD Coated Carbide Insert

2013 ◽  
Author(s):  
V. S. Senthil Kumar ◽  
C. Ezilarasan ◽  
A. Velayudham
Keyword(s):  
Acoustic Emission ◽  
Tool Wear ◽  
Wear Mechanisms ◽  
Gas Turbines ◽  
Cutting Conditions ◽  
Tool Wear Mechanisms ◽  
Cutting Velocity ◽  
Coated Carbide ◽  
Carbide Insert ◽  
Super Alloy

Due to its ability to resist thermal fatigue and creep resistance at higher temperature, nimonic C-263 super alloy is frequently applied in the hot combustion chamber of gas turbines. By virtue of the above they induce tool wear while machining which seriously affect the life of the component, and it is a serious concern, since it is used in critical applications. To monitor the status of the tool condition, several sensors are utilised, of which acoustic emission is most widely used due to its nature of generation phenomenon. In this paper PVD coated carbide insert is utilised to conduct tool wear study through turning of nimonic C-263 super alloy. The experiments were performed at different combinations of cutting conditions. The life of the cutting tool at different cutting conditions and the tool wear mechanisms were analysed. Results revealed that acoustic signal predict the condition well and that cutting velocity play a major role in the tool wear progression. Abrasion, micro chipping and plastic deformation are observed to be the major tool wear mechanisms.

Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 894-900 ◽  
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari ◽  
Nurhayati Ab. Razak
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Room Temperature ◽  
End Milling ◽  
Hardened Steel ◽  
Cutting Conditions ◽  
Preheating Temperature ◽  
Aisi H13 ◽  
Coated Carbide

Hardened materials like AISI H13 steel are generally regarded as s difficult to cut materials because of their hardness due to intense of carbon content, which however allows them to be used extensively in the hot working tools, dies and moulds. The challenges in machining steels at their hardened state led the way to many research works in amelioration its machinability. In this paper, preheating technique has been used to improve the machinability of H13 hardened steel for different cutting conditions. An experimental study has been performed to assess the effect of workpiece preheating using induction heating system to enhance the machinability of AISI H13. The preheated machining of AISI H13 for two different cutting conditions with TiAlN coated carbide tool is evaluated by examining tool wear, surface roughness and vibration. The advantages of preheated machining are demonstrated by a much extended tool life and stable cut as lower vibration/chatter amplitudes. The effects of preheating temperature were also investigated on the chip morphology during the end milling of AISI H13 tool steel, which resulted in reduction of chip serration frequency. The preheating temperature was maintained below the phase change temperature of AISI H13. The experimental results show that preheated machining led to appreciable increasing tool life compared to room temperature machining. Abrasive wear, attrition wear and diffusion wear are found to be a very prominent mechanism of tool wear. It has been also observed that preheated machining of the material lead to better surface roughness values as compared to room temperature machining.

scholarly journals Hard Turning ASSESSMENT on EN31 Steel in Dry and Wet Cooling Environments USING Grey-Fuzzy Hybrid Optimization APPROACH

2021 ◽  
Vol 13 (2) ◽  
pp. 55-62
Author(s):  
Saswat Khatai ◽  
◽  
Ramanuj Kumar ◽  
Ashok Kumar Sahoo ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Physical Vapor Deposition ◽  
Hard Turning ◽  
Removal Rate ◽  
Hybrid Optimization ◽  
Optimization Approach ◽  
Dry Cutting ◽  
Coated Carbide

In recent years, machining of hard-to-cut metals by hard turning process is an embryonic technology for machining industry and research development. Hard turning is generally defined as the material removal process of hardened steel having hardness greater than 45 HRC.  The current research presents a comparative hard turning investigation on EN 31 (56 ± 1 HRC) grade steel using physical vapor deposition (PVD) coated carbide tool under dry and wet cooling. The selection of a better cooling strategy among dry and wet cooling was based on the value of obtained surface roughness (Ra) and material removal rate (MRR) in hard turning. Wet cooling exhibited better performance over dry cutting as lower Ra and greater MRR are achieved with wet cooling. Further, considering Taguchi L16 orthogonal array, hard turning experiments were executed in wet cooling and responses like surface roughness (Ra), material removal rate (MRR), and diameter error were studied. Further, the Grey-fuzzy hybrid optimization tool was employed and found improved results relative to the alone grey relational analysis as about 9 % less Ra and 2.612 times more MRR is noticed at the grey fuzzy optimal set of parameters.

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