scholarly journals Experimental Investigation and Performance Analysis of Ceramic Inserts in Laser Assisted Turning of Waspaloy

2018 ◽  
Vol 237 ◽  
pp. 01003 ◽  
Author(s):  
Martyna Wiciak ◽  
Tadeusz Chwalczuk ◽  
Agata Felusiak
Keyword(s):  
Tool Wear ◽  
Laser Beam ◽  
Tool Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Heat Resistant Alloy ◽  
Nickel Based Superalloy ◽  
And Performance ◽  
Laser Assisted Turning

In this paper, the influence of laser assisted turning of hard-to-cut nickel-based superalloy on tool cutting ability was presented. The conducted research involved the machining performance along with tool life of ceramic inserts during turning of heat-resistant alloy under a trade name Waspaloy. The ceramic insert with geometry in accordance with the ISO – RPGX 120700 T01020 were applied during longitudinal turning with laser beam. The investigations has been completed with various cutting conditions such as laser power P, cutting speed vc, feed f and depth of cut ap. In order to determine the relations between the tool wear and cutting time, the tool life T has been selected. The increment of tool wear was correlated with the change of vibration signals and the critic points of tool wear was presented. In addition, the shape and form of chip was evaluated based on macroscopic observation and SEM analyses. The conducted research was primarily focused on effective application of ceramic inserts during turning Waspaloy with laser beam and comparison this technology with conventional machining.

Turning of SAE 1050 Steel With Vegetable Base Cutting Fluid

2012 ◽  
Author(s):  
Rosemar Batista da Silva ◽  
Álisson Rocha Machado ◽  
Déborah de Oliveira Almeida ◽  
Emmanuel O. Ezugwu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Manufacturing Companies ◽  
Machining Performance ◽  
Increase Tool Life

The study of cutting fluid performance in turning is of great importance because its optimization characteristics has associated benefits such as improved tool life and overall quality of machined components as well as reduction in power consumption during machining. However, there are recent concerns with the use of cutting fluids from the environmental and health standpoints. Since environmental legislation has become more rigorous, the option for “green machining” attracts the interest of several manufacturing companies. It is important to consider the cost of machining which is associated with tool wear, depending on the cutting environment. The use of vegetable oil may be an interesting alternative to minimize the health and environmental problems associated with cutting fluids without compromising machining performance. This paper presents a comparative study of mineral and vegetable cutting fluids in terms of tool wear after turning SAE 1050 steel grade with cemented carbide cutting tools. Constant depth of cut of 2mm and variable cutting speed (200 and 350 m/min) and feed rate (0.20 and 0.32 mm/rev) were employed. Test results suggest that is possible to achieve improvement in machinability of the material and increase tool life by using vegetable cutting fluid during machining. Tool life increased by about 85% when machining with vegetable-based fluids compared to mineral-based fluids. Analysis of the worn tools, however, revealed a more uniform wear on the worn flank face when machining with mineral-based fluids.

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Performance of Brazed Carbide End Mill Tool for Machining of Ti6Al4V

2014 ◽  
Vol 541-542 ◽  
pp. 363-367 ◽  
Author(s):  
Saad Nawaz ◽  
Li Xiao Xing ◽  
Zhou Chai
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Thermal Stresses ◽  
Elevated Temperatures ◽  
Aerospace Industry ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
End Mill

Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of Titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand Titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study brazed carbide end mill of grade 5 is used for rough down milling of Ti6Al4V for large depth of cut under different combinations of parameters and application of high pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, thermal crack and tool breaking. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal cracks were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. At cutting speed of 38m/min tool wear couldnt be observed due to tool failure because of fracture under high thermal stresses. It was found that maximum tool life is obtained at the speed of 25m/min, feed rate of 150mm/min and depth of cut of 10mm. In the end it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and fracture propagation.

Magnetic Damping in Turning of Stainless Steel AISI 304 for the Reduction of Machining Vibration and Tool Wear

2015 ◽  
Vol 1115 ◽  
pp. 100-103
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Siti Aminatuzzuhriyah B. Haji Subir ◽  
Fawaz Mohsen Abdullah
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Aisi 304 ◽  
Excited Vibration ◽  
Coated Carbide

Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.

Predictive Tool Life Model of CBN in Ti6Al4V High Speed Turning and Cutting Parameter Optimization

2009 ◽  
Vol 407-408 ◽  
pp. 594-598
Author(s):  
Xiao Qin Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Pei Quan Guo
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Efficiency ◽  
Predictive Tool ◽  
Cbn Tool ◽  
Small Depth ◽  
Cutting Parameter Optimization

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with CBN (Cubic Boron Nitride) in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of CBN tool. Finally, the cutting parameters of CBN tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the higher cutting speed and small depth of cut are the better selection, it means that utilization of CBN tool enables the high cutting speed turning of Ti6Al4V.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Analytical Study of the Effect of Heat Pipe Cooling in Machining

2005 ◽  
Author(s):  
Richard Y. Chiou ◽  
Vitaliy Aynbinder ◽  
L. G. Stepanskiy ◽  
Lin Lu ◽  
Shreepud Rauniar ◽  
...  
Keyword(s):  
Analytical Solution ◽  
Tool Wear ◽  
Heat Pipe ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Fluids ◽  
Tool Insert

Tool wear of machine tools and large usage of cutting fluids is one of the major problems in manufacturing. Cutting fluids are used to cool down the tool and have been shown to cause environmental problems in machine shops. Tool life and temperature have an inverse relationship, namely that the higher the temperature at the tool-chip interface is, the lower the tool life will be, and vice-versa. In this paper an innovative approach was taken to create an analytical solution to the effect of the embedded heat pipe on temperature of the tool and tool life. It has been well documented in the industry that the major factors that contribute to tool wear are the material properties of the tool insert and the work piece, cutting speed, depth of cut and feed rate. The analytical approach taken in this project is unique because it does not only take into account the complex boundary conditions of heat transfer but also the aforementioned factors and variety of possible cutting conditions. The analytical solution is in the form of set of equations which were developed to simulate the behavior of the tool insert under normal cutting conditions. Both cases, with and without heat-pipe were considered. The predicted temperature data was then compared to the existing experimental data, with very good results. In the end the project yields a quantitative evaluation on influence of mechanical properties of insert, work piece, heat pipe and cutting conditions on tool wear.

Empirical Expression of Tool Wear When Face Milling 416 SS

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Increase Tool Life ◽  
The Cost

During a machining process, cutting parameters must be taken into account, since depending on them the cutting edge starts to wear out to the point that tool can fail and needs to be change, which increases the cost and time of production. Since wear is a negative phenomenon on the cutting tool, due to the fact that tool life is reduced, it is important to optimize the cutting variables to be used during the machining process, in order to increase tool life. This research is focused on the influence of cutting parameters such as cutting speed, feed per tooth and axial depth of cut on tool wear during a face milling operation. The Taguchi method is applied in this study, since it uses a special design of orthogonal array to study the entire parameters space, with only few numbers of experiments. Also a relationship between tool wear and the cutting parameters is presented. For the studies, a martensitic 416 stainless steel was selected, due to the importance of this material in the machining of valve parts and pump shafts.

Implementation of Magnetic Damping to Reduce Chatter Amplitude and Tool Wear during Turning of Stainless Steel AISI 304

2014 ◽  
Vol 607 ◽  
pp. 171-175 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Ummu Atiqah Khairiyah Mohamad ◽  
Muammer Din Arif
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Machine Tool ◽  
Tool Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Aisi 304 ◽  
Magnetic Damping ◽  
Excited Vibration ◽  
Tool Shank

Machine tool chatter is a type of intensive self-excited vibration of the individual components in a machine-tool-fixture-work system. Chatter affects the cutting process and may lead to negative effects concerning surface quality, cutting tool life, and machining precision. However, modern manufacturing industries and their end users demand fine surface finish, high dimensional accuracy as well as low operation costs which include the cost of tooling. Therefore, any effective damping technique, which reduces or eliminates chatter, will significantly improve tool life and will be a profitable technique to implement in the industry. This paper presents a novel chatter control method in turning of (AISI 304) stainless steel by using permanent magnets. The study compared tool wear under two different cutting conditions: normal turning and turning with magnetic damping. A specail fixture made of mild steel was designed and fabricated in order to attach a powerful neodymium permanent magnet (4500 Gauss) to the carraige of a Harrison M390 engine lathe. The arrangement ensured that the magnet was placed exactly below the tool shank. The main idea was that the magnet will provide effective damping by attracting the steel tool shank and restricting its vertical vibratory motion during cutting operations. A Kistler 50g accelerometer, placed at the bottom front end of the tool shank was used to sense vibration. The data was then collected using a Dewetron DAQ module and analyzed using Dewesoft (version 7) software in a powerful Dell workstation. Response surface methodology (RSM) in Design Expert software (version 6) was used to design the sequence of experiments needed based on three primary cutting parameters: cutting speed, feed, and depth of cut. The tool overhang was kept constant at 120 mm in order to facilitate the attachment of the magnet fixture. Analysis of the recorded vibration signals in the frequency domain indicated that significant reduction in the vibration amplitude, as much as 86%, was obtained with magnetic damping. Next tool wear was analysed and measured using a scanning electron microscope (SEM). It is found that tool wear is reduced considerably by a maximum of 87.8% with the magnetic damping method. Therefore, this new magnetic damping method can be very cost effective, in terms of vibration reduction and tool life extension, if applied to industrial turning operations of metals.

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