Effect of Process Parameters on Tool Wear and Surface Roughness during Turning of Hardened Steel with Coated Ceramic Tool

Abstract In this study, an additive manufacturing process based on digital light processing was employed for quick, flexible, and economical fabrication of resin-bonded SiC grinding tools. The grinding wheel has been fabricated using laboratory manufacturing processes that utilize ultraviolet-curable resins and conventional abrasives. Also, desirable geometries and features like integrated coolant holes, which are difficult or even almost impossible to manufacture by conventional processes, are easily achievable. Grinding experiments were carried out by different process parameters, and with two different grinding wheels, i.e. with and without cooling channels with different concentrations (25 wt.% and 50 wt.% grains) to evaluate the grinding efficiency of the produced tools. Grinding forces, tool wear, tool loading, and ground surface quality were measured and analyzed. The wear rates of the grinding wheels with cooling channels were generally less than those without cooling channels, particularly in the deep grinding processes with large contact areas. Grinding tests on a hardened steel have shown that the integration of cooling lubricant channels almost prevents the wheel loading. In addition, by increasing the cutting speed (from 15 to 30 m/s) and decreasing the feed rate (from 10 to 2 m/min) the grinding wheel wear was significantly reduced. Furthermore, surface grinding of aluminum resulted in surface roughness values (Ra) in the range of 1 µm to 2.5 µm, while a Ra of about 0.2 µm was achieved by grinding hardened steel (100Cr6) with the same grinding conditions. Using the higher SiC-grain concentration (50 wt.%), it was determined that the surface roughness was 50% finer. Additionally the tool wear was significantly reduced (up to 30 times depending on the process parameters). The wear characteristics of the grinding wheel was analyzed through a novel image processing system. Significant correlations were found between wear flat of grains and the increase in grinding forces due to the tool wear.

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Digital light processing-based additive manufacturing of resin bonded SiC grinding wheels and their grinding performance

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-08016-z ◽

2021 ◽

Author(s):

Qingfeng Ai ◽

Jahangir Khosravi ◽

Bahman Azarhoushang ◽

Amir Daneshi ◽

Björn Becker

Keyword(s):

Surface Roughness ◽

Additive Manufacturing ◽

Tool Wear ◽

Process Parameters ◽

Hardened Steel ◽

Grinding Wheel ◽

Grinding Wheels ◽

Grinding Forces ◽

Digital Light Processing ◽

Cooling Channels

AbstractIn this study, an additive manufacturing process based on digital light processing was employed for a quick, flexible, and economical fabrication of resin bonded SiC grinding tools. The grinding wheel has been fabricated using laboratory manufacturing processes that utilize ultraviolet-curable resins and conventional abrasives. Also, desirable geometries and features like integrated coolant holes, which are difficult or even almost impossible to manufacture by conventional processes, are easily achievable. Grinding experiments were carried out by different process parameters, and with two different grinding wheels, i.e., with and without cooling channels with different concentrations (25 wt.% and 50 wt.% grains) to evaluate the grinding efficiency of the produced tools. Grinding forces, tool wear, tool loading, and ground surface quality were measured and analyzed. The wear rates of the grinding wheels with cooling channels were generally less than those without cooling channels, particularly in the deep grinding processes with large contact areas. Grinding tests on a hardened steel have shown that the integration of cooling lubricant channels almost prevents the wheel loading. In addition, by increasing the cutting speed (from 15 to 30 m/s) and decreasing the feed rate (from 10 to 2 m/min), the grinding wheel wear was significantly reduced. Furthermore, surface grinding of aluminum resulted in surface roughness values (Ra) in the range of 1 μm to 2.5 μm, while a Ra of about 0.2 μm was achieved by grinding hardened steel (100Cr6) with the same grinding conditions. Using the higher SiC-grain concentration (50 wt.%), it was determined that the surface roughness was 50% finer. Additionally the tool wear was significantly reduced (up to 30 times depending on the process parameters). The wear characteristics of the grinding wheel were analyzed through a novel image processing system. Significant correlations were found between the wear flat of grains and the increase in grinding forces due to the tool wear.

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Experimental research on the deep-hole boring of pure niobium tube

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

10.1177/0954405420905980 ◽

2020 ◽

Vol 234 (8) ◽

pp. 1124-1132

Author(s):

Xiaolan Han ◽

Zhanfeng Liu ◽

Yazhou Feng

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Experimental Research ◽

Process Parameters ◽

Cutting Tool ◽

Geometric Parameters ◽

Deep Hole ◽

High Quality ◽

Pure Niobium ◽

Hole Axis

In the deep-hole boring process on pure niobium tube, there exist some problems including serious tool wear, tough chips, and poor surface quality. In order to bore high-quality deep holes on rolled niobium tube, the cutting tool structure and boring process parameters suitable for machining rolled niobium tube were designed and two experimental schemes were proposed. The results showed that the geometric parameters of the cutting tool and process parameters have important influences on the tool wear, chip morphologies, hole-axis deflection, and hole surface roughness. By adjusting the geometric parameters of the cutting tool and boring process parameters, reasonable geometric parameters of the cutting tool and boring process parameters were obtained.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.894 ◽

2011 ◽

Vol 264-265 ◽

pp. 894-900 ◽

Cited By ~ 1

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.

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Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

Materials ◽

10.3390/ma14206106 ◽

2021 ◽

Vol 14 (20) ◽

pp. 6106

Author(s):

Waleed Ahmed ◽

Hussien Hegab ◽

Atef Mohany ◽

Hossam Kishawy

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Inclination Angle ◽

Feed Rate ◽

Cutting Speed ◽

Weight Ratio ◽

Hardened Steel ◽

Machining Process ◽

Aisi 4140 ◽

Steel Aisi

It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle were the selected design variables, while the tool wear, surface roughness, and material removal rate (MRR) were the studied outputs. The optimal surface roughness was obtained at a cutting speed of 240 m/min, an inclination angle of 20°, and a feed rate of 0.1 mm/rev. In addition, the minimum flank tool wear was observed at a cutting speed of 70 m/min, an inclination angle of 10°, and a feed rate of 0.15 mm/rev. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer’s interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140 within the selected ranges.

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Effects of Process Parameters on Material Removal in Vibration-Assisted Polishing of Micro-Optic Mold

Micromachines ◽

10.3390/mi9070349 ◽

2018 ◽

Vol 9 (7) ◽

pp. 349 ◽

Cited By ~ 3

Author(s):

Jiang Guo ◽

Hirofumi Suzuki

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Removal Efficiency ◽

Process Parameters ◽

Material Removal ◽

Removal Rate ◽

Grain Sizes ◽

Tool Influence Function ◽

Polishing Pressure ◽

Lower Material

Process parameter conditions such as vibrating motion, abrasives, pressure and tool wear play an important role in vibration-assisted polishing of micro-optic molds as they strongly affect material removal efficiency and stability. This paper presents an analytical and experimental investigation on the effects of process parameters, aimed at clarifying interrelations between material removal and process parameters which affect polishing quantitatively. The material removal rate (MRR) and surface roughness which represent the polishing characteristics were examined under different vibrating motions, grain sizes of abrasives and polishing pressure. The effects of pressure and tool wear conditions on tool influence function were analyzed. The results showed that 2D vibrating motion generated better surface roughness with higher material removal efficiency while a smaller grain size of abrasives created better surface roughness but lower material removal efficiency. MRR gradually decreases with the increase of polishing pressure when it exceeds 345 kPa, and it was greatly affected by the wear of polisher when wear diameter on the polisher’s head exceeds 300 μm.

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Investigation of Tool Wear, Tool Life and Surface Roughness when Machining AISI D2 Hardened Steel Using PVD TiAlN Coated Carbide Tools

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.465-466.1098 ◽

2013 ◽

Vol 465-466 ◽

pp. 1098-1102 ◽

Cited By ~ 2

Author(s):

Noor Hakim Rafai ◽

Mohd Amri Lajis ◽

N.A.J. Hosni

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Tool Life ◽

Material Removal ◽

Cutting Tools ◽

Hardened Steel ◽

Tool Failure ◽

Aisi D2 ◽

Wear Tool ◽

Coated Carbide

This paper discussed the behavior of cutting tool in terms of tool wear, tool life and surface roughness when machining an AISI D2 hardened steel. An experimental test was conducted at different cutting speeds (Vc) and radial depth of cut (ae) using PVD TiAlN coated carbide tool under dry condition. Tool failure modes and tool wear mechanism for all cutting tools were examined at various cutting parameters. Flank wear was found to be the predominant tool failure for cutting tools. The highest volume material removal (VMR) attained was 3750 mm3 meanwhile the highest tool life (TL) was 9.69 min. The surface roughness (Ra) values from 0.09 to 0.24 μm can be attained in the workpiece with a high material removal. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high material removal, maximum tool life as well as acceptable surface finish.

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