MECHANICAL PROPERTIES AND CUTTING PERFORMANCE OF ELECTROLESS TERNARY NI-W-P COATED CUTTING TOOLS

2017 ◽  
Vol 79 (5-2) ◽  
Author(s):  
Mohd Sanusi Abdul Aziz ◽  
Bahrin Ikram Redzuwan ◽  
Muhammad Zaimi ◽  
Raja Izamshah ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Surface Roughness ◽  
Tool Life ◽  
Electrical Power ◽  
Cutting Tools ◽  
Electroless Nickel ◽  
Cutting Performance ◽  
High Deposition Rate ◽  
Nickel Deposition ◽  
Plating Bath

This paper presents a new approach of electroless nickel deposition (END) on cutting tools as to enhance tool performance. END involves several reactions in aqueous solution and is performed without using electrical power. The cutting performance of electroless ternary Ni-W-P alloy-coated cutting tools that were prepared in plating baths with different pH levels and with the addition of heat treatment was investigated. The cutting tool life was evaluated during machining on AISI D2 steel followed by measurement of surface roughness. Experimental results showed that END cutting tools produced from a plating bath with a pH of 8.5 with heat treatment resulted in the longest tool life, which was 7 minutes 32 seconds, and the lowest surface roughness, which was 0.412 μm. High deposition rate and high thickness of coating obtained under such pH condition were found to be the main factors in enhancing tool life. Furthermore, the addition of heat treatment increases the hardness and improves the coating surface.

Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

2014 ◽  
Vol 800-801 ◽  
pp. 191-196
Author(s):  
Bin Zhao ◽  
Han Lian Liu ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Hong Tao Zhu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Nickel Based Superalloy ◽  
Coated Tool ◽  
Optimal Cutting Parameters ◽  
Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

Cutting Performance of Reaming Alloy Gray Cast Iron HT250 Using Carbide, Cermet and CBN Reamers

2018 ◽  
Vol 764 ◽  
pp. 261-270 ◽  
Author(s):  
X.K. Yang ◽  
Y.G. Wang ◽  
W.L. Ge ◽  
L. Chen ◽  
H. Ge
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Tool Life ◽  
Gray Cast Iron ◽  
Cutting Parameters ◽  
Hole Diameter ◽  
Cutting Performance ◽  
Gray Cast ◽  
Suitable Material ◽  
Spindle Power

Cutting performance of reaming alloy gray cast iron HT250 using carbide, cermet and CBN reamers was studied. Experiments were conducted under constant cutting parameters and cooling strategy. Tool life, hole diameter, spindle power, surface roughness and tool wear were analyzed. The hole diameter and spindle power would keep steady when reaming with carbide reamer after 400 holes to the tool life of 1050 holes. But holes diameter reduced and spindle power increased with the number of machined holes increasing during the whole tool life when using cermet or CBN reamer. The surface roughness Rz of the holes reamed by carbide reamer was within the tolerance, although it was worse than that reamed by cermet and CBN reamer. It can be summarized that the carbide was the most suitable material for reaming alloy gray cast iron because of the longest tool life, steady hole diameter and spindle power, qualified surface roughness. After machining, crater wear and clearance wear were produced on the cermet and CBN reamer, which were caused by abrasive wear. In addition, flaking and breakages appeared on the edge of cermet reamer, which were not found on CBN reamer. However, the clearance wear of carbide reamer was smaller than that of CBN reamer, and built up edge was found along the cutting edge.

Effects of Complexing Agent Concentration and Bath pH on Electroless Nickel Deposition for Tungsten Carbide Powders

2014 ◽  
Vol 970 ◽  
pp. 240-243 ◽  
Author(s):  
Pranee Rattanawaleedirojn ◽  
Kanokwan Saengkiettiyut ◽  
Yuttanant Boonyongmaneerat ◽  
Nutthita Chuankrerkkul ◽  
Sawalee Saenapitak
Keyword(s):  
Tungsten Carbide ◽  
Deposition Rate ◽  
Electroless Nickel ◽  
Powder Injection ◽  
Complexing Agent ◽  
Chemical Compositions ◽  
High Deposition Rate ◽  
Nickel Deposition ◽  
Moulding Process ◽  
Injection Moulding Process

An elemental nickel (Ni) or cobalt (Co) is typically introduced to tungsten carbide (WC) prior to powder injection moulding process (PIM) for hard metal fabrication to enhance toughness and tool life. Mixing of powders is normally practiced, although it requires a long processing time for homogeneous mixing. In this study, as an alternative method, an addition of Ni via the electroless deposition method is investigated. The key process parameters, including the concentration of the complexing agent, namely sodium citrate, and bath pH, are systematically examined in relation to deposition rate and deposits size, microstructure, and chemical compositions. As the bath pH is increased to higher alkalinity of 10 and the Ni ion to complexing agent mole ratio is controlled under 1:1, a stable electroless nickel solution and a relatively high deposition rate with about 15% weight gain for 1 hour deposition duration are achieved. The phosphorus (P) content, obtained in the range of 5-9 wt%, is largely influenced by the bath pH. While a rapid deposition rate is associated with preferentially deposition of Ni on pre-deposited Ni sites, a low to moderately high deposition rate results in more uniform incorporation of Ni-P alloys in WC powder mixture.

scholarly journals Experimental Investigation on the Advantages of Dry Machining over Wet Machining during Turning of AISI 1020 Steel

2021 ◽  
Vol 8 ◽  
pp. 12-25
Author(s):  
Boki Dugo Bedada ◽  
Guteta Kabeta Woyesssa ◽  
Moera Gutu Jiru ◽  
Besufekad Negash Fetene ◽  
Tekle Gemechu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Dry Machining ◽  
Dry Turning ◽  
Total Cost ◽  
Cemented Carbide Tool ◽  
Lathe Machine ◽  
The Cost

In this study, the experiment was conducted to investigate the advantage of dry machining over wet machining during turning of AISI 1020 steel using cemented carbide tool on a CNC lathe machine. Surface roughness and cutting temperature were measured by VOGEL surface roughness tester and infrared thermometer respectively. The experiments were conducted based on Taguchi L9 orthogonal array design. Surface roughness, cutting temperature, tool life, and machining cost were analyzed graphically. The average surface roughness and cutting temperature achieved with wet machining was 2.01 μm and 26.540C, which was 17.41% and 44.86% respectively, lower than dry machining. The high cutting temperature in dry turning result in short tool life, which was 41.15% shorter than wet turning. The machining cost of wet turning was about 56% greater than the cost of dry turning. The cost of coolant in wet turning is 42.88% greater than that of the cutting tools. The highest cost was shared by tool cost, which was 81.33% of the total cost for dry turning, while 70.00% of the total cost was shared by coolant cost for wet turning. Results revealed that dry turning is more economical than wet turning.

Investigating of Tool Wear, Tool Life and Surface Roughness When Machining of Nickel Alloy 242 with Using of Different Cutting Tools

2008 ◽  
Vol 1 (3) ◽  
pp. 222-230 ◽  
Author(s):  
H.H. Habeeb ◽  
K.A. Abou-El-Ho ◽  
Bashir Mohamad ◽  
Jahara A. Ghani ◽  
K. Kadirgama
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Nickel Alloy ◽  
Tool Life ◽  
Cutting Tools ◽  
Wear Tool

PROPERTIES OF ALUMINIUM/ELECTROLESS Ni-COATED SiC COMPOSITES - A REVIEW

2021 ◽  
Vol 5 (1) ◽  
pp. 381-391
Author(s):  
H. Odiwo ◽  
K. A. Bello ◽  
M. Abdulwahab ◽  
A. A. Adebisi ◽  
M. A. Maleque
Keyword(s):  
Heat Treatment ◽  
Sol Gel ◽  
Direct Interaction ◽  
Casting Process ◽  
Electroless Nickel ◽  
Matrix Alloy ◽  
Stir Casting ◽  
Nickel Deposition ◽  
Sic Particulates ◽  
Sic Composites

The combination of properties of Al/SiC composites make them very attractive materials for applications in automotive and aerospace industries. Several techniques are used in developing Al/SiC composites but stir casting process is most commonly used because it is the simplest and cost effective technique. However, composites produced via stir casting suffer from limitations such as low wettability and inadequate bonding between the molten Al & SiC particulates and the formation of degrading interfacial products like aluminum carbide (Al4C3) which degrades the mechanical properties of the composite. Some of the techniques to improve Al-SiC wettability include addition of surface active elements such as magnesium, heat treatment of particles and application of metallic coating on the reinforcements before addition to the melt. Wetting agents alter the composition of the matrix alloy, while heat treatment of the reinforcement does not completely prevent the formation of Al4C3 when utilized. To reduce the direct interaction and promote wetting between reinforcements and molten aluminum during processing, the surface of SiC particulates can be modified by coating via oxidation, sol-gel and electroless processes. Of all these methods, electroless nickel deposition produces the best coatings with uniform thickness and adequate strength. In the present study, influence of electroless nickel-coating of SiC on the mechanical, corrosion and microstructural properties of Al/SiC composite has been evaluated. Finally, it can be concluded that the Ni and Ni3P intermetallic phases produced via electroless coating improves the wettability between the SiC and molten aluminium leading to enhanced properties of the composite.

Investigation of Tool Wear, Tool Life and Surface Roughness when Machining AISI D2 Hardened Steel Using PVD TiAlN Coated Carbide Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1098-1102 ◽  
Author(s):  
Noor Hakim Rafai ◽  
Mohd Amri Lajis ◽  
N.A.J. Hosni
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Material Removal ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Tool Failure ◽  
Aisi D2 ◽  
Wear Tool ◽  
Coated Carbide

This paper discussed the behavior of cutting tool in terms of tool wear, tool life and surface roughness when machining an AISI D2 hardened steel. An experimental test was conducted at different cutting speeds (Vc) and radial depth of cut (ae) using PVD TiAlN coated carbide tool under dry condition. Tool failure modes and tool wear mechanism for all cutting tools were examined at various cutting parameters. Flank wear was found to be the predominant tool failure for cutting tools. The highest volume material removal (VMR) attained was 3750 mm3 meanwhile the highest tool life (TL) was 9.69 min. The surface roughness (Ra) values from 0.09 to 0.24 μm can be attained in the workpiece with a high material removal. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high material removal, maximum tool life as well as acceptable surface finish.

PCD Reamer for Machining Cylinder Head

2011 ◽  
Vol 175 ◽  
pp. 321-325
Author(s):  
Yong Guo Wang ◽  
Xiao Guang Chen ◽  
Gang Liu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cylinder Head ◽  
Cutting Tools ◽  
Al Alloy ◽  
Cutting Efficiency ◽  
German Company ◽  
Machined Parts ◽  
Automobile Parts ◽  
Better Than

PCD cutting tools have been widely used in manufacturing main automobile parts such as Al-alloy cylinder head and block. Being used PCD cutting tools, the cutting efficiency and precision of the machined parts could be increased. 4 blades PCD reamer used for reaming Al-alloy cylinder head has been development. Results showed that the tool life of this reamer is 2 times than the similar tools made by German company, the surface roughness is Ra0.2, better than the required Ra0.8, the cylindricity is 0.003, better than the required 0.006.

scholarly journals Study on the Cutting Performance of Micro Textured Tools on Cutting Ti-6Al-4V Titanium Alloy

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 137 ◽  
Author(s):  
Kairui Zheng ◽  
Fazhan Yang ◽  
Na Zhang ◽  
Qingyu Liu ◽  
Fulin Jiang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Feed Force ◽  
Cemented Carbide Tools

Titanium alloys are widely used in various fields, but their machinability is poor because the chip would easily adhere to the tool surface during cutting, causing poor surface quality and tool wear. To improve the cutting performance of titanium alloy Ti-6Al-4V, experiments were conducted to investigate the effect of micro textured tool on the cutting performances. The cemented carbide tools whose rake faces were machined with line, rhombic, and sinusoidal groove textures with 10% area occupancy rates were adopted as the cutting tools. The effects of cutting depth and cutting speed on feed force and main cutting force were discussed based on experimental results. The results show that the cutting force produced by textured tools is less than that produced by non-textured tools. Under different cutting parameters, the best cutting performance can be obtained by using sinusoidal textured tools among the four types of tools. The wear of micro textured tools is significantly lower than that of non-textured tools, due to a continuous lubrication film between the chip and the rake face of the tool that can be produced because the micro texture can store and replenish lubricant. The surface roughness obtained using the textured tool is better than that using the non-textured tool. The surface roughness Ra can be reduced by 35.89% when using sinusoidal textured tools. This study is helpful for further improving the cutting performance of cemented carbide tools on titanium alloy and prolonging tool life.

scholarly journals Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1628
Author(s):  
Mohd Fathullah Ghazali ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Paweł Pietrusiewicz ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Potential Use

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

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