scholarly journals Tool Wear Analysis of Coated Carbide Tools on Cutting Force in Machining Process of AISI 4140 Steel

2020 ◽  
Vol 852 ◽  
pp. 012083
Author(s):  
Sobron Lubis ◽  
Rosehan ◽  
Steven Darmawan ◽  
Benny Indra
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Machining Process ◽  
Aisi 4140 Steel ◽  
Wear Analysis ◽  
Aisi 4140 ◽  
Coated Carbide ◽  
Coated Carbide Tools

scholarly journals VARIASI KECEPATAN PEMOTONGAN PROSES PEMBUBUTAN BAJA AISI 4140 TERHADAP KEAUSAN DAN UMUR MATA PAHAT KARBIDA

POROS ◽  
2021 ◽  
Vol 17 (1) ◽  
pp. 26
Author(s):  
Sobron Y. Lubis ◽  
Sofyan Djamil ◽  
Adianto Adianto ◽  
Amor Santosa ◽  
Edric VM.
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Aisi 4140 Steel ◽  
Steel Material ◽  
Aisi 4140 ◽  
Edge Wear ◽  
Coated Carbide

In the machining process, increased production can be done by increasing the use of cuttingparameters. However, the use of high cutting parameters has an effect on the wear of the cutting toolused. The aim of this research is to analyze the wear and tear that occurs on cutting tools and tool lifewhen cutting AISI 4140 steel by using variations in cutting speed. The machining process uses a CNClathe by turning the surface of the AISI 4140 steel workpiece. The wear criteria are determined when thecutting tool has reached the edge wear limit (VB) of 0.3 mm. Observation and measurement of carbidecutting tools are carried out every 5 minutes the machining process is carried out. If the cutting tool hasnot shown the specified wear value, then the cutting tool then cuts, so that the wear value is obtained.From the research conducted it was found that at a cutting speed of 160 m / min the cutting tool iscapable of cutting for 39 minutes, 13 seconds. At a cutting speed of 180 m / min the cutting tool is capableof cutting for 38 minutes, 14 seconds. At a cutting speed of 200 m / min the cutting tool is capable ofcutting for 33 minutes, 8 seconds. At a cutting speed of 240 m / min the cutting tool is capable of cuttingfor 26 minutes, 3 seconds. Taylor's advanced tool life for the coated carbide cutting tool in turning AISI4140 steel material is: Vc. Tl.0.073 = 8203.

Correlative Flank Wear Analysis of Single Point Turning Inserts Using Acoustic Emission and Artificial Intelligence Techniques

2008 ◽  
Author(s):  
R. Srinidhi ◽  
Vishal Sharma ◽  
M. Sukumar ◽  
C. S. Venkatesha
Keyword(s):  
Acoustic Emission ◽  
Tool Wear ◽  
Flank Wear ◽  
Machining Process ◽  
Work Piece ◽  
Machining Parameters ◽  
Wear Analysis ◽  
Tools Wear ◽  
Coated Carbide ◽  
Ae Signals

Wear mechanism of a cutting tool is highly complex in that the processes of tool wear results from interacting effect of machining configurations. Various output generated by the study and analysis of each tool is extremely useful in analyzing the tool characteristics in general and to make efforts to obtain the estimated tool life in particular. The gradual process of tool wear has adverse influence on the quality of the surface generated and on the design specifications in the work piece dimensions and geometry, and causes, at the worst case, machine breakdown. Advanced manufacturing demands proper use of the right tool and emphasizes the need to check the wear rate. A scientific method of obtaining conditions for an optimal machining process with proper tools and control of machining parameters is essential in the present day manufacturing processes. Many problems that affect optimization are related to the diminished machine performance caused by worn out tools. One of the indirect methods of tool wear analysis and monitoring is based on the acoustic emission (AE) signals. The generation of the AE signals directly in the cutting zone makes them very sensitive to changes in the cutting process and provides a means of evaluating the wear of cutting tools. Wear parameters obtained in the process are analyzed with the output generated by using Multi Layer Perceptron (MLP) based back propagation technique and Adaptive Neuro Fuzzy Interference System (ANFIS). The results obtained from these methods are correlated for the actual and predicted wear. Experiments have been conducted on EN8 and, EN24 using Uncoated Carbide, Coated carbide and Ceramic inserts (Kennametal, India make) on a high speed lathe for the most appropriate cutting conditions. The AE signal analysis (considering signal parameters such as, ring down count (RDC), rise time (RTT), event duration (ED) and energy (EG). Flank wear in tools and corresponding cutting forces for each of the trials are measured and are correlated for various combinations of tools and materials of work piece.

Tool Wear Analysis of MTConnect Production Data

2021 ◽  
Author(s):  
David Stock ◽  
Aditi Mukhopadhyay ◽  
Rob Potter ◽  
Andy Henderson
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Numerical Control ◽  
Machining Process ◽  
Total Load ◽  
Wear Rates ◽  
Wear Analysis ◽  
Nc Program ◽  
Small Set ◽  
Key Steps

Abstract This paper presents the analysis of data collected using the MTConnect protocol from a lathe with a Computer Numerical Control (CNC). The purpose of the analysis is to determine an estimated cutting tool life and generate a model for calculating a real-time proxy of cutting tool wear. Various streams were used like spindle load, NC program blocks, the mode, execution etc. The novelty of this approach is that no information about the machining process, beyond the data provided by the machine, was necessary to determine the tool’s expected life. This method relies on the facts that a) it is generally accepted cutting loads increase with tool wear and b) that many CNC machines rely on a small set of regularly run CNC programs. These facts are leveraged to extract the total load for each run of each program on the machine, creating a dataset which is a good indicator of tool wear and replacement. The presented methodology has four key steps: extracting cycle metadata from the machine execution data; computing the integrated spindle loads for every cycle; normalizing the integrated spindle loads between different programs; extracting tool wear rates and changes from the resulting dataset. It is shown that the method can successfully extract the signature of tool wear under a common set of circumstances which are discussed in detail.

Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

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.

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

2019 ◽  
Vol 234 (4) ◽  
pp. 701-709
Author(s):  
Tao Chen ◽  
Weijie Gao ◽  
Guangyue Wang ◽  
Xianli Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Two Sides

Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

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.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

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