scholarly journals Method for assessing the thermophysical properties of the contact pair ‘tool – steel workpiece’

2021 ◽  
Vol 2131 (5) ◽  
pp. 052012
Author(s):  
Yu Chigirinskiy ◽  
Zh Tikhonova ◽  
D Kraynev
Keyword(s):  
Tool Steel ◽  
Cutting Speed ◽  
Contact Pair ◽  
Carbide Tool ◽  
Steel Billet ◽  
Coated Carbide Tool ◽  
Coated Tool ◽  
Indirect Indicator ◽  
Coated Carbide ◽  
Tool Durability

Abstract To The analysis of methods for evaluating the properties of contact pairs “hard -alloy coated tool-steel billet” is carried out in order to use them to increase the reliability of the choice of turning modes in the generations of CNC systems equipped with technological intelligence. It is proposed to use the value of the thermo-emf of the test pass as an indirect indicator of the properties of contact pairs composed of a coated carbide tool and a processed steel billet. Models for calculating the cutting speed based on a given tool durability period of a coated carbide tool and predicting the actual cutting tool durability period for given processing conditions are proposed by introducing into their structure an additional informative value about the properties of each contact pair - the thermo-EMF of the test pass. The conducted resistance tests of various carbide plates during the processing of P-group steels showed sufficient reliability of the proposed dependences.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

Wear mechanism of a coated carbide tool in cryogenic machining of AISI 4340

2019 ◽  
Vol 72 (4) ◽  
pp. 509-514 ◽  
Author(s):  
Shalina Sheik Muhamad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron ◽  
Hafizal Yazid
Keyword(s):  
Wear Mechanisms ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Carbide Tool ◽  
Cryogenic Machining ◽  
Content Type ◽  
Coated Carbide Tool ◽  
Adhesion Wear ◽  
Coated Carbide ◽  
Aisi 4340

Purpose The purpose of this study is to investigate wear mechanisms of a multi-layered TiAlN/AlCrN-coated carbide tool during the milling of AISI 4340 steel under cryogenic machining. Design/methodology/approach The wear progression was measured using a toolmaker microscope and an optical microscope. Later, a field emission scanning electron microscope and energy-dispersive X-ray analysis were used to investigate the wear mechanisms in detail. Findings A comprehensive analysis revealed that the main causes of tool wear mechanisms were abrasion and adhesion wear on the flank face. Originality/value The investigations presented in this paper may be used by the machining industry to prolong the tool life at higher cutting speed by the application of liquid nitrogen.

Improving coated carbide tool life through wide peening cleaning (WPC) during the wet milling of H13 tool steel

Wear ◽  
2020 ◽  
Vol 450-451 ◽  
pp. 203259
Author(s):  
Shahereen Chowdhury ◽  
Bipasha Bose ◽  
Abul Fazal M. Arif ◽  
Stephen C. Veldhuis
Keyword(s):  
Tool Life ◽  
Tool Steel ◽  
Carbide Tool ◽  
Wet Milling ◽  
H13 Tool Steel ◽  
Coated Carbide Tool ◽  
Coated Carbide

The Effects of TiAlN and TiN Coating during End Milling of INCONEL 718

2014 ◽  
Vol 564 ◽  
pp. 566-571
Author(s):  
K. Kamdani ◽  
Sulaiman Hasan ◽  
Mohd Amri Lajis
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Speed ◽  
Extreme Condition ◽  
Carbide Tool ◽  
Coated Carbide Tool ◽  
Coated Carbide

Inconel 718 is a registered trademark of Special Metals Corporation that refers to a family of austenitic nickel-chromium-based super alloys. This material usually being used or operate in high temperature and extreme condition like aerospace industry, turbocharger rotors and seals. This research presents an experimental study of the cutting force variation, surface roughness, tool life and tool wear in end milling Inconel 718. The experimental results showed that flank wear was the predominant failure mode affecting tool life for TiAlN and TiN coated carbide tool. TiAlN is the better coated tool than TiN because it produce better surface finish and resultant force. Feed rate is one of the parameter that effecting results in this experiment. The higher feed rate will shorten the life of the tool. Although for the cutting condition, the situation is quite different where the proper cutting speed will maintain the tool life and tool wear for cutting tool. The overall study shows that TiAlN coated carbide tool with cutting speed 100 m/min, depth of cut 0.5 mm and feed rate 0.1 mm/tooth is the optimum parameter in this experiment.

Reliability and economic analysis in sustainable machining of Monel 400 alloy

2021 ◽  
pp. 095440622098681
Author(s):  
Ashwani Tayal ◽  
Nirmal Singh Kalsi ◽  
Munish Kumar Gupta ◽  
A Garcia-Collado ◽  
Murat Sarikaya
Keyword(s):  
Surface Roughness ◽  
Economic Analysis ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Turning ◽  
Sustainable Machining ◽  
Coated Carbide Tool ◽  
Prime Concern ◽  
Coated Carbide

Engineering field nurtures a variety of superalloys and its wide applications due to the inherent properties of such material. The prime concern of working engineers is to explore reliability, quality, economy, and machinability analysis of these superalloys. In this work, sustainable machining of Monel 400superalloy using PVD multilayer coated carbide tool under dry turning was studied. Surface roughness (Ra, Rz, and Rq), power (P) and cutting force (Fc) were addressed as responses. The subsequent effect of cutting speed, feed and depth of cut on the responses was explored through response surface methodology (RSM), statistical analysis of variance (ANOVA) and multiple regression analysis. Details of tool wear was observed via scanning electron microscope (SEM) to know the cutting behavior at interface. Further, the reliability and economic analysis were performed to substantiate the feasibility of cutting insert. The investigation reveals that surface roughness was affected by feed and cutting speed. The increase in cutting speed uncovers lower cutting forces with improved surface finish during dry turning which further reduces the power requirement. The economic analysis shows unit production time and unit production cost based on a single insert PVD coated carbide tool under optimum value condition. The reliability analysis exposes the meantime to repair (MTTR) (5 min), mean time between failure (MTBF) (28 min), availability (84.8%), failure rate (0.03), and reliability (80.5%) for the production system.

scholarly journals Optimization of Cutting Parameters to Minimize Tooling Cost in High Speed Turning of SS304 using Coated Carbide Tool using Genetic Algorithm Method

2016 ◽  
Vol 1 (1) ◽  
pp. 11-15
Author(s):  
Muataz Hazza ◽  
Nur Amirah Najwa
Keyword(s):  
Genetic Algorithm ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Carbide Tool ◽  
High Speed Turning ◽  
Coated Carbide Tool ◽  
Optimization Of Cutting Parameters ◽  
Coated Carbide

High speed turning (HST) is an approach that can be used to increase the material removal rate (MRR) by higher cutting speed. Increasing MRR will lead to shortening time to market. In contrast, increasing the cutting speed will lead to increasing the flank wear rate and then the tooling cost.  However, the main factor that will justify the best level of cutting speed is the tooling cost which merges all in one understandable measurable factor for manufacturer. The aim of this paper is to determine experimentally the optimum cutting levels that minimize the tooling cost in machining AISI 304 as a work piece machined by a coated carbide tool using one of the non-conventional methods: Genetic Algorithm (GA). The experiments were designed using Box Behnken Design (BBD) as part of Response Surface Methodology (RSM) with three input factors: cutting speed, feeding speed and depth of cut.

Investigations on Machinability Characteristics of Hardened AISI H13 Steel With Multilayer Coated Carbide Tool Using Statistical Techniques

2017 ◽  
pp. 194-207
Author(s):  
R. Suresh ◽  
Ajith G. Joshi
Keyword(s):  
Feed Rate ◽  
Cutting Speed ◽  
Statistical Techniques ◽  
Carbide Tool ◽  
H13 Steel ◽  
Aisi H13 Steel ◽  
High Cutting Speed ◽  
Coated Carbide Tool ◽  
Aisi H13 ◽  
Coated Carbide

Hard turning with multilayer coated carbide tool has several benefits over grinding process such as, reduction of processing cost and increased productivity. The objective was to establish a correlation between cutting parameters with cutting force, tool wear and surface roughness on workpiece. In the present study, machinability of AISI H13 steel with TiC/TiCN/Al2O3 coated carbide tool using statistical techniques. An attempt has been made to analyze the effects of process parameters on machinability aspects using design of experiments. Response surface plots are generated for the study of interaction effects of cutting conditions on machinability factors. The obtained results revealed that, the optimal combination of low feed rate and low depth of cut with high cutting speed is beneficial for reducing machining force. The cutting tool wears increases almost linearly with increase in cutting speed and feed rate. The combination of low feed rate and high cutting speed is necessary for minimizing the surface roughness.

Wear Mechanism of High-Speed Turning Ti-6Al-4V with TiAlN and AlTiN Coated Tools in Dry and MQL Conditions

2012 ◽  
Vol 497 ◽  
pp. 30-34 ◽  
Author(s):  
Jin Yang Xu ◽  
Zhi Qiang Liu ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
Carbide Tool ◽  
High Speed Turning ◽  
Coated Carbide Tool ◽  
Coated Tool ◽  
Coated Carbide ◽  
Oxidation Wear

The TiAlN and AlTiN coated carbide cutting tools were adopted for high-speed turning of α+β phase titanium alloy Ti-6Al-4V. Both the wear pattern and wear mechanism were investigated in this research. Results show that: MQL condition can greatly prolong the tool life of AlTiN coated carbide tool but has minor influence on improving the tool life of TiAlN carbide tool. AlTiN coated carbide tool was found to be qualified to obtain better cutting performance and longer tool life and is more suitable for processing titanium alloy TC4 compared with TiAlN coated tool under the same cutting parameters. In dry cutting condition, both adhesive and oxidation wear were observed to be the main wear types in these two coated carbide tools. However, in MQL condition, TiAlN coated tool may only suffer adhesive wear while the AlTiN coated carbide tool suffer adhesive, diffusion and oxidation wear.

Tool Life Prediction and Cutting Parameter Optimization for Coated Carbide in Ti6Al4V Turning

2012 ◽  
Vol 426 ◽  
pp. 186-189
Author(s):  
X.Q Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
X.L. Fu ◽  
Y. Z. Pan
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Contour Analysis ◽  
Cutting Efficiency ◽  
Coated Carbide Tool ◽  
Cutting Parameter Optimization ◽  
Coated Carbide

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with coated carbide 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 coated carbide tool. Finally, the cutting parameters of coated carbide tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the lower cutting speed and larger depth of cut are the better selection in Ti6Al4V turning for coated carbide tool.

Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

2021 ◽  
pp. 095440622199384
Author(s):  
Lalatendu Dash ◽  
Smita Padhan ◽  
Anshuman Das ◽  
Sudhansu Ranjan Das
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Sustainability Assessment ◽  
Flank Wear ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Carbide Tool ◽  
Minimum Quantity ◽  
Coated Carbide Tool ◽  
Coated Carbide

The present research addresses the machinability of hardened die steel (AISI D3, 61HRC) in hard turning using multilayer (TiCN/Al2O3/TiN) coated carbide tool under nanofluid based minimum quantity lubrication-cooling condition, where no previous data are available. Power consumption, flank wear, chip morphology and surface integrity (microhardness, residual stress, white layer formation, machined surface morphology, and surface roughness) are considered as technological performance characteristics to evaluate the machinability. Combined approach of central composite design - analysis of variance, response surface methodology and desirability function analysis have been employed respectively for experimental investigation, predictive modelling and multi-response optimization. With a motivational philosophy of “Go Green-Think Green-Act Green”, the work also deals with energy saving carbon footprint analysis and sustainability assessment to recognize the green manufacturing in the context of safer and cleaner production. under environmental-friendly nanofluid assisted minimum quantity lubrication condition. The quantitative analysis revealed that the cutting speed influenced the power consumption during hard machining (75.78%) and flank wear of coated carbide tool (45.67%); feed rate impacted the surface finish of the machined part (68.8%) significantly. Saw tooth shapes of chip produced due to cyclic cracking. Due to low percentage contribution of error (5.32% to Ra, 6.64% to VB, and 7.79% to Pc), a higher correlation coefficient (R2) was obtained with the quadratic regression model, which showed values of 0.9, 0.88 and 0.92 for surface roughness, flank wear, and power consumption, respectively. Optimization with the highest desirability (0.9173) resulted the optimum machining conditions under NFMQL at the cutting speed of 57 m/min, depth of cut 0.1 mm, feed of 0.07 mm/rev, and insert’s nose radius of 0.4 mm. As a result, under NFMQL tool life was improved by 30.8% and 22.6% in respect of flank wear and surface roughness respectively than when machining with MQL technique by adapting the optimum machining condition. Therefore, using hard nanoparticles-reinforced cutting fluid under minimum quantity lubrication condition in practical manufacturing becomes very promising to improve sustainability.

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