Effect of metal cutting fluid (MCF) conditions on tool wear and thrust force in drilling Ti-6Al-4V using coated carbide tools

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

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Performance comparison of coated carbide tool under different cooling/lubrication environments during face milling of Inconel-625 and Stainless Steel 304

World Journal of Engineering ◽

10.1108/wje-06-2018-0194 ◽

2019 ◽

Vol 16 (2) ◽

pp. 287-295 ◽

Cited By ~ 1

Author(s):

Pragat Singh ◽

J.S. Dureja ◽

Harwinder Singh ◽

Manpreet S. Bhatti

Keyword(s):

Tool Wear ◽

Wear Behavior ◽

Face Milling ◽

Cutting Fluid ◽

Inconel 625 ◽

Machining Performance ◽

Content Type ◽

Stainless Steel 304 ◽

Coated Carbide ◽

Ss 304

PurposeThis study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).Design/methodology/approachMachining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.FindingsThe results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.Research limitations/implicationsInconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.Originality/valueThe literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

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Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.33.173 ◽

2010 ◽

Vol 33 ◽

pp. 173-176

Author(s):

X.Y. Wang ◽

S.Q. Pang ◽

Q.X. Yu

Keyword(s):

Tool Wear ◽

Tool Life ◽

Experimental Research ◽

Cutting Tools ◽

Cutting Speed ◽

Life Testing ◽

Processing Efficiency ◽

Comparative Tests ◽

Coated Carbide ◽

Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

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Effects of Cutting Parameters on Tool Wear and Thrust Force in Drilling Nickel-Titanium (NiTi) Alloys Using Coated and Uncoated Carbide Tools

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.791.111 ◽

2018 ◽

Vol 791 ◽

pp. 111-115 ◽

Cited By ~ 1

Author(s):

Rosmahidayu Rosnan ◽

Azwan Iskandar Azmi ◽

Muhamad Nasir Murad

Keyword(s):

Wear Resistance ◽

Tool Wear ◽

Thrust Force ◽

Cutting Parameters ◽

Nickel Titanium ◽

Burr Formation ◽

Machining Processes ◽

Drilling Parameters ◽

Mechanical Machining ◽

Coated Carbide

The difficulties of machining nickel-titanium alloys are due to their high ductility and super-elasticity, strong strain-hardening, and excellent wear resistance. These characteristics lead to poor chip breakability, high cutting forces, rapid and aggressive tool-wear, as well as excessive burr formation during mechanical machining processes. The present study addresses these issues by evaluating the effects of drilling parameters and drill bit coatings on the growth of tool wear and development of the drilling thrust force. The findings from this research indicate that the TiAlN coated carbide drill was found to significantly improve the wear resistance of the cutting tool. Likewise, the results of thrust force development are consistent with the trends of tool wear growth for all of the tested carbide drills.

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Comparative Assessment of Coated CBN and Multilayer Coated Carbide Tools on Tool Wear in Hard Turning AISID2 Steel

SSRN Electronic Journal ◽

10.2139/ssrn.3323677 ◽

2018 ◽

Author(s):

M.Junaid Mir ◽

M.F. Wani ◽

Summera Banday ◽

Shuhaib Mushtaq ◽

Jebran Khan ◽

...

Keyword(s):

Tool Wear ◽

Hard Turning ◽

Comparative Assessment ◽

Coated Carbide ◽

Coated Carbide Tools

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Optimization of Cutting Conditions in Milling Process to Minimize Tool Wear Using Selected Soft Computing Techniques: A Comparative Study

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686714500048 ◽

2014 ◽

Vol 13 (01) ◽

pp. 55-72 ◽

Cited By ~ 2

Author(s):

Vikas Pare ◽

Geeta Agnihotri ◽

Chimata Murali Krishna

Keyword(s):

Tool Wear ◽

Soft Computing ◽

Metal Cutting ◽

Removal Rate ◽

Cutting Speed ◽

Helix Angle ◽

Pattern Search ◽

Cutting Fluid ◽

Soft Computing Techniques ◽

Input Parameters

The life of a tool is very significant in metal cutting because production time is a waste whenever a tool is replaced or reset. Because of prolonged use, cutting tools blunt and their effectiveness decreases over time. It is necessary to replace, index or resharpen, and reset the tool after certain time. Tool life is a measure of the length of time a tool will cut effectively. The life of a cutting tool is mostly affected by many factors, such as, the tool wear, material removal rate, microstructure of the material being cut, setup rigidity, and cutting fluid quality. In this paper, up-milling and down-milling are compared with respect to different input parameters mainly cutting speed, feed, and number of teeth, rake angle, and helix angle. A relationship between tool wear and these input parameters is established by using regression analysis and soft computing techniques are applied to minimize the tool wear. Five selected soft computing techniques viz. (i) Genetic Algorithm (GA), (ii) Simulated Annealing (SA), (iii) Hybrid GA with Pattern Search (PS), (iv) Particle Swarm Optimization (PSO), and (v) Threshold Acceptance Algorithm (TAA), are used for optimization of tool wear. The results obtained from each of them are also analyzed. The effect of input parameters on tool wear, the way it is different for up-milling and down-milling is addressed for each case with the help of five selected soft computing techniques. The results indicate that the tool wear is least in case of down-milling when compared to up-milling and hybrid GA gave the best results.

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Tool Wear Investigation on Dry Electrostatic Cooling in Turning Titanium Alloy Ti6Al4V

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.2058 ◽

2010 ◽

Vol 97-101 ◽

pp. 2058-2061 ◽

Cited By ~ 5

Author(s):

Hui Wang ◽

Rong Di Han ◽

Yang Wang

Keyword(s):

Titanium Alloy ◽

Tool Wear ◽

Tool Life ◽

Metal Cutting ◽

Cutting Speed ◽

Cutting Fluid ◽

Dry Cutting ◽

Set Up ◽

Titanium Alloy Ti6al4v ◽

Emulsion Oil

The machinability of Titanium Alloy Ti6Al4V is poor, the traditional methods to machining is application of cutting fluids with the active additives which cause environmental pollution and health problems. In this paper, the dry electrostatic cooling was applied instead of cutting fluid for the aim of green cutting Ti6Al4V. The ionized device and gas supply system was set up, the effects of dry electrostatic cooling, emulsion oil and dry cutting on tool wear have been examined in turning of Ti6Al4V with carbide tools YG8, the curve between tool flank wear and cutting time was proposed, and the equation between cutting speed and tool life was set up. The results of experiments indicated that application of dry electrostatic cooling reduced the tool wear and increased the tool life. The research results show that clean production was achieved in metal cutting associated with dry electrostatic cooling.

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