scholarly journals Keutuhan Permukaan Bahan Keluli Perkakas Setelah Pengisaran Hujung Menggunakan Perkakas Karbida Bersalut

2012 ◽  
Author(s):  
Che Hassan Che Haron ◽  
Andanastuti Muchtar ◽  
Nik Faizu Nik Kundor
Keyword(s):  
Tool Steel ◽  
Surface Integrity ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Machined Surface ◽  
Aisi D2 ◽  
Coated Carbide

Projek ini dijalankan bertujuan untuk mengkaji kesan proses pengisaran terhadap keutuhan permukaan keluli perkakas D2. Dalam kajian ini, keluli perkakas kerja sejuk AISI D2 yang telah dikeraskan kepada 62 HRC dimesin menggunakan sisip karbida bersalut CVD boleh indeks yang dipegang oleh perkakas pengisaran hujung berdiameter 20 mm. Siri–siri ujian dijalankan dalam keadaan kering. Penilaian ke atas permukaan yang dimesin melibatkan kekasaran permukaan dan analisis mikrostruktur. Keputusan kajian menunjukkan bahawa tiada hubungan yang jelas di antara variasi kelajuan pemotongan dan suapan terhadap kekasaran permukaan. Umumnya, permukaan yang dihasilkan adalah sangat licin dengan nilai Ra berada dalam julat 0.10 μm – 0.43 μm dan analisis permukaan pada sampel–sampel ujikaji juga mendapati hampir tiada perubahan dapat dikesan pada mikrostruktur bahagian bawah permukaan yang dimesin. Walau bagaimanapun, pada kelajuan pemotongan tertinggi (160 m/min) dan suapan yang tinggi (0.02 mm/sisip), terdapat kesan termampat dan terherot pada mikrostruktur pada kedalaman yang sangat cetek iaitu lebih kurang 2.2 μm dari permukaan termesin. Kata kunci: Keutuhan permukaan, keluli perkakas terkeras, pengisaran hujung, mikrostruktur, perkakas karbida bersalut The effect of milling process on the surface integrity of newly machined surface of D2 tool steel is presented. The hardened AISI D2 (62 HRC) was machined under dry cutting conditions using a 20 mm diameter end–milling tool with indexable CVD coated carbide insert. Analyses revealed that the variation in cutting speeded and feed did not significantly affect the surface roughness of the machined surface. Generally, the surfaces produced are very smooth with Ra values in the range of 0.1 – 0.43 μm, and studies showed almost no microstructure alteration on the machined surfaces. However, at the highest cutting condition, i.e. a cutting speed of 160 m/min, and feed of 0.02 mm/tooth, some compression and distortion effects were detected on the microstructure at the very shallow depth of approximately 2.2 μm from the machined surface. Key words: Surface integrity, hardened tool steel, end-milling, microstructure, coated carbide tool

A Study of Surface Integrity when Machining Refractory Titanium Alloys

2009 ◽  
Vol 83-86 ◽  
pp. 1059-1068 ◽  
Author(s):  
Armansyah Ginting ◽  
Mohammed Nouari ◽  
Nadhir Lebaal
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Surface Integrity ◽  
Bulk Material ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Feed Speed ◽  
Machined Surface ◽  
Feed Mark ◽  
Coated Carbide

In this paper, the surface integrity is studied when machining the aeronautical titanium alloys. Surface roughness, lay, defects, microhardness and microstructure alterations are studied. The result of surface roughness judges that the CVD-coated carbide fails to produce better Ra value than the uncoated. Lay is characterized by cutting speed and feed speed directions. Feed mark, tearing surface, chip layer formation as built up layer (BUL), and deposited microchip are the defects. Microhardness is altered down to 350 microns beneath the machined surface. The first 50 microns is the soft sub-surface caused by thermal softening in ageing process. Microstructure alteration is observed in this sub-surface. Down to 200 microns is the hard sub-surface caused by the cyclic internal work hardening and then it is gradually decreasing to the bulk material hardness. It is concluded that dry machining titanium alloy is possible using uncoated carbide with cutting condition limited to finish or semi-finish for minimizing surface integrity alteration.

Effect of Milling Parameters and Coolants on Surface Hardness of Tool Steel: SKD 11

2013 ◽  
Vol 650 ◽  
pp. 596-601
Author(s):  
Apichad Inkhamnoi ◽  
Komson Jirapattarasilp
Keyword(s):  
Tool Steel ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Milling Process ◽  
Dry Cutting ◽  
Machined Surface ◽  
Milling Parameters ◽  
The Face

The purpose of this research was to study milling parameters and coolant, which were affecting to surface hardness of tool steel: SKD 11. The experiment was design by conduction of 3 factors and 3 levels. The parameters consisted of three levels of cutting speed and three levels of feed rate. Furthermore, the experiment was done by coolant types. Soluble oil vegetable oil and dry-cutting were used for coolant types in milling. The face milling process was chosen to experiment. Cutting tool was used for this study was inserted carbide with coated polycrystalline vapor deposited (PVD) tools. The finding of main factors and interaction between factors affected to surface hardness was analyzed. Effect of cutting speed and feed rate on surface hardness after milling was discussed. In order to finding suitable of coolant type, effect of coolants on hardness of machined surface was analyzed and compared.

Surface Integrity in Hot Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 500 ◽  
pp. 44-50 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim
Keyword(s):  
Induction Heating ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Heating Temperature ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Aisi D2 ◽  
Hot Machining ◽  
Coated Carbide

This study presents experimental results of machined surface integrity of die material (AISI D2 hardened steel) when hot machining (induction heating) assisted end milling using coated carbide is applied. The aim of this work was to study the influence of induction heating temperature, cutting speed, and feed on the effects induced by hard milling on surface integrity (microhardness and work-hardening). Microhardness was measured to observe the distribution of the hardness beneath the surface and to determine the effect of induction heating on the micro-hardness distribution and work-hardening phenomena. The behaviour of microhardness induced in the subsurface region when end milling under room and induction heating cutting conditions using coated carbide inserts was also investigated. The surface integrity and subsurface alteration have been investigated by employing scanning electron microscope (SEM) and Vickers microhardness tester.

Tool Wear Analysis in End Milling of Advanced Ceramics with TiAlN and TiN Coated Carbide Inserts

2012 ◽  
Vol 576 ◽  
pp. 76-79
Author(s):  
M. Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein ◽  
D. Sujan ◽  
Mohammad Yeakub Ali ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
High Hardness ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Carbide ◽  
Axial Depth

Advanced ceramic materials are difficult to machine by conventional methods due to the brittle nature and high hardness. The appropriate selection of cutting tool and cutting conditions may help to improve machinability by endmilling. Performance of TiAlN and TiN coated carbide tool insert in end milling of machinable glass ceramic has been investigated. Several dry cutting tests were performed to select the optimum cutting parameters for the endmilling in order to obtain better tool life. In this work, a study was carried out on the influence of cutting speed, feed rate and axial depth of cut on tool wear.The technique of design of experiments (DOE) was used for the planning and analysis of the experiments. Tool wear prediction model was developed using Response surface methodology.The results indicate that tool wear increased with increasing the cutting speed and axial depth of cut. Effect of feed rate is not much significant on selected range of cutting condition

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Yunn-Shiuan Liao ◽  
Tsung-Hsien Li ◽  
Yi-Chen Liu
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Liquid Carbon ◽  
Dry Cutting ◽  
Machined Surface ◽  
Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

Effect of Machining Parameters and MQL Liquids on Surface Integrity of High Speed Drilling Ti-6Al-4V

2010 ◽  
Vol 447-448 ◽  
pp. 816-820 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Roughness ◽  
Palm Oil ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
High Speed Drilling ◽  
Coated Carbide

Surface integrity is particularly important for the aerospace industry components in order to permit longer service life and maximized its reliability. This present work compares the performance of palm oil and synthetic ester on surface roughness, surface defect, microhardness and subsurface deformation when high speed drilling of Ti-6Al-4V under MQL condition. The drilling tests were conducted with AlTiN coated carbide tool. The surface roughness decreased with increasing in cutting speed and thicker subsurface deformation was formed underneath the machined surface. Grooves, cavities, pit holes, microcracks and material smearing were the dominant surface damages thus deteriorated the machined surface. For both lubricants, the machined surface experienced from thermal softening and work hardening effect thus gave a variation in microhardness values. The results indicated the substantial benefit of MQL by palm oil on surface integrity.

Modeling & Optimization of Surface Roughness & Vibration Amplitude in Heat Assisted End Milling of SKD 11 Tool Steel Using Ball Nose Tool

2012 ◽  
Vol 538-541 ◽  
pp. 799-803 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Muhd Hafiz B. Md. Saad ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Tool Steel ◽  
Vibration Amplitude ◽  
End Milling ◽  
Heating Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Primary Input ◽  
Coated Carbide

Tool steel - SKD 11 is frequently used in industries for making dies and molds. This grade is chosen for its toughness, strength, and hardness maintained up to high temperature. However, the same properties make the steel extremely difficult and expensive to machine using conventional approaches. Heat assisted machining has been found wide spread application in recent years to improve machinability of difficult-to-cut materials. This research paper presents the outcome of an investigation on heat assisted end milling of SKD 11 conducted on a vertical machining center using ball nose coated carbide inserts. The Design of Experiments (DoE) was done using the Response Surface Methodology, in order to develop empirical mathematical models of surface roughness and vibration in terms of cutting speed, feed, axial depth of cut, and heating temperature. The models were checked for significance using Analysis of Variance (ANOVA). 3-D response surface graphs of the interactions of primary cutting parameters with the responses were plotted. Optimization was then performed by using the desirability function approach. From the graphs and optimized results it was concluded that the primary input parameters could be controlled in order to reduce vibration amplitude and produce semi-finished machined surfaces applying induction heat assisted technique.

Experimental Study on Nano-TiAlN Coated Carbide Tools in Turning Austenitic Stainless Steel

2012 ◽  
Vol 723 ◽  
pp. 247-251
Author(s):  
Hai Dong Yang ◽  
Zhi Ding
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Dry Cutting ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Austenitic stainless steel has poor cutting performance, especially when the inappropriate choice of tool materials and cutting parameters, cutting tool life will be shortened and the quality of machined surface is poor. In this paper, 0Cr18Ni9 stainless steel dry cutting tests had been done with nano-TiAlN coated carbide blade YGB202, the relationship between tool life and cutting speed, tool wear mechanism had been analyzed. In order to improve the processing efficiency and tool life, process parameters were optimized.

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