Wear characteristics of nano TiAlN-coated carbide tools in ultra-high speed machining of AerMet100

Wear ◽  
2012 ◽  
Vol 289 ◽  
pp. 124-131 ◽  
Author(s):  
Guosheng Su ◽  
Zhanqiang Liu
Keyword(s):  
High Speed ◽  
High Speed Machining ◽  
Wear Characteristics ◽  
Ultra High Speed ◽  
Coated Carbide ◽  
Coated Carbide Tools

Wear and cutting forces in high-speed machining of H13 using physical vapour deposition coated carbide tools

2005 ◽  
Vol 219 (2) ◽  
pp. 191-199 ◽  
Author(s):  
P T Mativenga ◽  
K K B Hon
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Vapour Deposition ◽  
High Speed Machining ◽  
Physical Vapour Deposition ◽  
Tin Coatings ◽  
Tool Coatings ◽  
Process Trends ◽  
Coated Carbide ◽  
Coated Carbide Tools

This paper reviews the contributions that coatings make in enhancing the cutting performance of carbide tools and, in particular, their application in high-speed machining. It examines flank wear and cutting force process trends that are essential for monitoring tool degradation in automated machining factories. The findings of the investigation into cutting forces over the life cycle of different physical vapour deposition (PVD) tool coatings on micrograin carbide in the high-speed machining of tool steel are presented and related to the existing literature. Cutting tests were carried out at a very high spindle speed, 40000 r/min, and for a predetermined cutting time. Variants of the TiAlN coating, i.e. single- and double-layer and composite coating enhanced with WC/C, were evaluated against the uncoated tool and the TiCN, CrN, and TiN coatings. The paper reflects on the performance of advanced PVD coatings and also presents force trends and suggestions for process monitoring.

Wear Mechanism Analysis of Coated Carbide Tools in High-Speed Milling of Ti-6Al-4V Alloy via Cross-Section Characterization of Worn Cutting Edge

2015 ◽  
Author(s):  
Anhai Li ◽  
Jun Zhao ◽  
Fenghua Lin
Keyword(s):  
Cross Section ◽  
Wear Mechanisms ◽  
High Speed ◽  
Tool Material ◽  
Cutting Edge ◽  
High Speed Machining ◽  
Erosion Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

Tool wear analysis is essential in high speed machining, especially in the intermittent cutting and milling processes. Analyses of tool wear mechanisms will be beneficial for proposing the suggestions in the tool design process how to enhance the tool material properties to improve the cutting performance and eventually tool life. Wear mechanisms of coated carbide tools in high-speed dry milling of Ti-6A1-4V were assessed by characterization of the cross-section of worn tool cutting edge utilizing scanning electron microscopy, and the element distribution of the worn tool surface was detected by using energy dispersive spectroscopy. Results show that flank wear, chipping and flaking of tool material on the rake face and/or at the nose of tools were the dominant failure modes. And synergistic interaction among coating delamination, erosion wear, adhesion, dissolution-diffusion wear, and thermal-mechanical fatigue wear were the main wear mechanisms analyzed from cross-sectional worn cutting edge. Erosion wear was identified in high speed milling of Titanium alloy and introduced into the wear mechanisms of metal cutting tools. The hydromechanics characteristic of the chips produced in high-speed machining should be responsible for erosion wear of cuttings tools.

Modeling Machining at High Speeds as a Fluid Mechanics Problem

2008 ◽  
Author(s):  
Roman V. Kazban ◽  
James J. Mason
Keyword(s):  
Fluid Mechanics ◽  
Stagnation Point ◽  
Potential Flow ◽  
High Speed ◽  
Material Behavior ◽  
High Speed Machining ◽  
Flow Solution ◽  
High Speeds ◽  
Ultra High Speed ◽  
Very High

Even though many models for machining exist, most of them are for low-speed machining, where momentum is negligible and material behavior is well approximated by quasi-static plastic constitutive laws. In machining at high speeds, momentum can be important and the strain rate can be exceedingly high. For these reasons, a fluid mechanics approach to understanding high-speed, very high-speed, and ultra-high-speed machining is attempted here. Namely, a potential flow solution is used to model the behavior of the material around a sharp tool tip during machining at high speeds. It is carefully argued that the potential flow solution is relevant and can be used as a first approximation to model the behavior of a metal during high-speed, very high-speed, or ultra-high-speed machining events; and at a minimum, the potential flow solution is qualitatively useful in understanding mechanics of machining at high speeds and above. Interestingly, the flow solution predicts that there is a stagnation point on the rake face, not at the tool tip as is usually assumed. Because the stagnation point is not at the tool tip, the flow solution predicts a significant amount of deformation in the workpiece resulting in large residual strains that may lead to a temperature rise on the finished surface.

Wear and breakage of TiAlN- and TiSiN-coated carbide tools during high-speed milling of hardened steel

Wear ◽  
2015 ◽  
Vol 336-337 ◽  
pp. 29-42 ◽  
Author(s):  
C.Y. Wang ◽  
Y.X. Xie ◽  
Z. Qin ◽  
H.S. Lin ◽  
Y.H. Yuan ◽  
...  
Keyword(s):  
High Speed ◽  
Hardened Steel ◽  
High Speed Milling ◽  
Coated Carbide ◽  
Coated Carbide Tools

162 Development of High-Functional Tap for realizing Ultra High Speed Machining

2014 ◽  
Vol 2014.49 (0) ◽  
pp. 121-122
Author(s):  
Yasuyoshi SAITO ◽  
Takeshi YAMAGUCHI ◽  
Kei SHIBATA ◽  
Yuki KADOTA ◽  
Takeshi KUBO ◽  
...  
Keyword(s):  
High Speed ◽  
High Speed Machining ◽  
Ultra High Speed

Ultra-High-Speed Machining: A Review and an Analysis of Cutting Forces

1973 ◽  
Vol 187 (1) ◽  
pp. 625-634 ◽  
Author(s):  
G. Arndt
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Physical Factors ◽  
High Speed Machining ◽  
Work Related ◽  
Rate Dependent ◽  
High Speeds ◽  
Ultra High Speed ◽  
Very High ◽  
Cutting Speeds

As part of the search for a new cutting mechanism, a few largely empirical investigations into ultra-high-speed machining (velocity greater than 500 ft/s) have been performed in the past. A comprehensive review of this and other work related to machining at very high cutting speeds is presented and the physical factors predominating in UHSM are discussed. As a consequence of this a new theory of cutting forces at ultra-high speeds is presented, based on inertia and temperature effects, adiabatic shear, and strain-rate dependent yield stress. This theory shows that workpiece properties greatly influence force behaviour, the latter determining the feasibility of machining at ultra-high speeds.

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