Machining Performance of PM Material Containing MnX Additives1

2000 ◽  
Vol 122 (4) ◽  
pp. 379-383 ◽  
Author(s):  
Stuart Barnes ◽  
Michael J. Nash ◽  
Moh. H. Lim
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
Superior Performance ◽  
Machining Performance ◽  
Turning Operation ◽  
Cutting Speeds

A new free-machining additive, MnX, has been reported to improve the machining performance of ferrous powder metallurgy (PM) materials. This work investigated this claim by comparing the performance of three otherwise identical PM materials containing: no additive, conventional manganese sulphide (MnS) additions and the new MnX additive. A turning operation and cutting speeds of 100–250 m/min were used during which cutting forces, tool wear and surface finish were measured. The MnX material was found to exhibit superior performance. However, this was most noticeable at higher cutting speeds and at the lower cutting speeds, differences in performance were substantially reduced. [S0094-4289(00)02004-1]

Machining Performance of PM Material Containing MnX Additives

1999 ◽  
Author(s):  
S. Barnes ◽  
M. J. Nash ◽  
M. H. Lim
Keyword(s):  
Powder Metallurgy ◽  
Cutting Speed ◽  
Superior Performance ◽  
Metal Powders ◽  
Machining Performance ◽  
Basic Composition ◽  
The Third ◽  
Trade Name ◽  
Carbide Inserts ◽  
Cutting Speeds

Abstract Improvements in the machining performance of ferrous powder metallurgy (PM) materials has recently been reported by one of the main manufacturers of metal powders. This improvement in machinability reportedly being achieved by the addition of a new free-machining additive which is marketed under the trade name of “MnX”. The work reported here, investigated this claim by comparing the performance of three PM materials with the same basic composition but different free-machining additives. The first material contained no free-machining additive, the second, contained the conventional manganese sulphide (MnS) additive and the third contained the new MnX additive. A turning operation was used to compare the performance of the three materials at cutting speeds in the range of 100–250 m/min using titanium nitride (TiN) coated UE6005 carbide inserts. The relative performance of the three materials was compared by measuring cutting forces, tool wear and the surface finish produced on the workpiece. It was found that at all cutting speeds investigated, the material containing MnX gave a superior performance. However, at higher cutting speeds the superiority of the material containing MnX was much more significant. In contrast, at the lowest cutting speed of 100 m/min, it was found that although the material containing MnX continued to exhibit the best performance, the differences between the three materials were substantially reduced and the material containing no free machining additive actually generated slightly less wear than the material containing MnS. The results therefore confirm that the new MnX additive is superior to the conventional MnS additive. However, this work has also demonstrated that relatively high cutting speeds are needed in order to obtain optimum benefits from the new additive.

Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

2007 ◽  
Author(s):  
Niniza S. P. Dlamini ◽  
Iakovos Sigalas ◽  
Andreas Koursaris
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Crater Wear ◽  
Compacted Graphite ◽  
Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

ASSESSING THE TRIBOLOGICAL PROPERTIES OF VEGETABLE OIL EMULSIONS AND MACHINING PARAMETER OPTIMIZATION USING RESPONSE SURFACE METHODOLOGY

2021 ◽  
Author(s):  
D. K. KARUPANNASAMY ◽  
M. SAMBATHKUMAR ◽  
R. GUKENDRAN ◽  
K. S. K. SASIKUMAR ◽  
N. BAASKARAN ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Tool Wear ◽  
Response Surface ◽  
Surface Finish ◽  
Castor Oil ◽  
Mineral Oil ◽  
Machining Process ◽  
Neem Oil ◽  
Machining Performance ◽  
Oil Emulsions

Bio-degradable lubricants are the need for industries to promote eco-friendly manufacturing process and protect the workers from health hazards. In this paper, the use of oil–water emulsions from the bio-substitute oils have been formulated and its process parameter on a machining process are optimized using response surface methodology. The emulsions are prepared from the vegetable oils such as castor, mahua, palm and neem oil with polysorbate as emulsifying agent. The friction and wear characteristics are studied with a standard pin on disc tribometer for all the emulsions prepared with the base oils namely castor, mahua and palm oil. From the tribological characterization tests, the castor oil emulsions have shown better performance and stability in comparison to other oils. Hence, castor oil emulsions have been tested for its machining performance studies against a conventional mineral oil emulsion in a turning process. Further, an emulsion based on castor oil and neem oil have been tested for tool wear to utilize the antimicrobial properties of neem oil for reducing the bio fouling effects. The machining performance is indicated based on the surface finish and tool wear. Response surface methodology have been used for optimization of the machining parameters, such as cutting velocity, feed rate and depth of cut to achieve an optimal surface finish for a maximum material removal rate. The results show that the castor oil based emulsion can be used as an excellent alternative for mineral oil emulsions.

Through-Tool Coolant Drilling of Aluminum/SiC Metal Matrix Composite1

2000 ◽  
Vol 122 (4) ◽  
pp. 384-388 ◽  
Author(s):  
Stuart Barnes ◽  
Ian R. Pashby
Keyword(s):  
Tool Wear ◽  
Beneficial Effect ◽  
Titanium Nitride ◽  
Surface Finish ◽  
Strong Evidence ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Solid Carbide ◽  
Cutting Operation ◽  
Tool Cooling

Through-tool coolant was applied to the drilling of an aluminum/SiC MMC. Titanium nitride coated, solid carbide drills were used to investigate the effect of the coolant application method on the performance of the drilling operation. Holes were produced dry, with conventional coolant and with through-the tool coolant. The results provided strong evidence that the conventional application of coolant was having no beneficial effect on the cutting operation compared to dry drilling. However, through-tool cooling gave a significant improvement in performance in terms of tool wear, cutting forces, surface finish and the height of the burrs produced. [S0094-4289(00)02104-6]

Effect of Cutting Parameters on Cutting Forces for Different Profile of Cutting

2015 ◽  
Vol 799-800 ◽  
pp. 361-365 ◽  
Author(s):  
Roshaliza Hamidon ◽  
Erry Y.T. Adesta ◽  
Muhammad Riza ◽  
Mohammad Iqbal
Keyword(s):  
Surface Finish ◽  
Orthogonal Array ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Anova Analysis ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Influential Parameters ◽  
Cutting Speeds

In machining operation of mould cavities, the tool travels in various straight and corner profiles following predetermined toolpath. Such condition results in a fluctuation of cutting forces that may produce bad surface finish. The objective of this study is to investigate the most influential parameters on cutting operation for both straight and corner profiles of pocketing operation. Cutting speeds of 150, 200 and 250m/min, feedrates from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were selected for the cutting processes. Taguchi L9 orthogonal array with Pareto ANOVA analysis was employed to analyze the effects of the selected parameters. The result demonstrates there are different effects of cutting parameters on cutting forces for straight and corner profiles. Furthermore, it was found that cutting speed and feedrate are prevailing factors that affected cutting forces for both types of profile.

Experimental Investigations to Study the Effect of Solid Lubricant MOS2 on the Performance of Hard Turning

2010 ◽  
Author(s):  
Dilbag Singh ◽  
P. Venkateswara Rao
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
Hard Turning ◽  
Solid Lubricant ◽  
Research Work ◽  
Cryogenic Cooling ◽  
Experimental Investigations ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Molybdenum Disulphide

In hard turning, lot of heat is generated due to plastic deformation of the work material, friction at the tool-chip interface and friction between tool and the workpiece. The heat produced in machining adversely affects the quality of the products produced. Cutting fluids have been the conventional choice to deal with this problem. However, due to the environmental restrictions, the use of cutting fluids is restricted. Machining with solid lubricants, cryogenic cooling by liquid nitrogen and minimum quantity lubrication are some of the alternative approaches in this direction. This research work deals with an investigation on using molybdenum disulphide as solid lubricant in order to reduce friction for improving the machining performance and for overcoming some of the limitations that arise due to the use of cutting fluids or while dry hard turning. An experimental setup has been designed and built, and experiments have been conducted to study the effect of using molybdenum disulphide as solid lubricant on surface finish and cutting forces. An improvement in surface finish was observed with molybdenum disulphide assisted hard turning. It was also observed that there was a considerable reduction of cutting forces, thereby reducing the specific energy needed and consequently improving the machining performance.

Cutting forces, tool wear and surface finish in high speed diamond machining

2017 ◽  
Vol 49 ◽  
pp. 293-304 ◽  
Author(s):  
Ekkard Brinksmeier ◽  
Werner Preuss ◽  
Oltmann Riemer ◽  
Rüdiger Rentsch
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
High Speed ◽  
Diamond Machining

Study on Effect of Ultrasonic Vibration in Machining of Alumina Ceramic

2012 ◽  
Vol 516 ◽  
pp. 311-316 ◽  
Author(s):  
Kyung Hee Park ◽  
Kyeong Tae Kim ◽  
Yun Hyuck Hong ◽  
Hon Jong Choi ◽  
Young Jae Choi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Ultrasonic Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Combination Technique

Ultrasonic machining can be applied for the machining of difficult-to-cut materials using ultrasonical oscillation in an axial direction on top of tool rotation, which can cause reduction of cutting temperature and tool wear. In this study, the experiments were performed on a DMG ULTRASONIC 20 linear machine tool using diamond tools in both conventional and ultrasonic vibration assisted machining. The machining performance was evaluated and compared for both cases in terms of cutting forces, machined surface roughness and tool wear. And the combination technique of 3D surface topography measurement and image processing was applied for the tool wear progress. Overall, the experimental results showed that ultrasonic machining had less tool wear and lower cutting forces at low cutting speed compared to conventional machining. Also surface roughness was slightly lower in ultrasonic machining than that without ultrasonic vibration.

Performance of Tungsten Carbide, Titanium Carbide, and Oxide Tools in Finish Turning of C-30 Gray Iron

1965 ◽  
Vol 87 (3) ◽  
pp. 344-348
Author(s):  
I. Ham ◽  
T. Hoshi ◽  
G. L. Thuering
Keyword(s):  
Tool Wear ◽  
Titanium Carbide ◽  
Tungsten Carbide ◽  
Surface Finish ◽  
Gray Iron ◽  
Depth Of Cut ◽  
Comparative Performance ◽  
Finish Turning ◽  
C 30 ◽  
Cutting Speeds

Performance data were obtained for tungsten carbide, titanium carbide, and oxide tools in the finish turning of C-30 gray iron. Characteristics of typical wear patterns were examined in relation to their effects on cutting force and surface finish. Using both surface finish and tool wear as tool life criteria, the comparative performance of these tools was evaluated. The oxide tool was superior to the carbide tools except at low cutting speeds. The influence of depth of cut and of a prehoned land on the cutting edge was also studied.

On the improvement of process performance of hard turning using vibration-assisted machining

2021 ◽  
pp. 251659842110080
Author(s):  
Pranesh Dutta ◽  
Gaurav Bartarya
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
Cutting Forces ◽  
Hard Turning ◽  
Fe Model ◽  
Process Performance ◽  
Machining Performance ◽  
Cutting Velocity ◽  
Low Amplitude ◽  
Conventional Machining

In hard turning, the cutting forces are large, which leads to tool wear and tensile nature of residual stresses. Vibration-assisted machining (VAM), where the tool is provided with a low amplitude vibration at significantly high frequency, might improve the process performance of hard turning in terms of cutting forces, residual stress, etc., as VAM helps in reduction of cutting forces and tool wear significantly. To improve the machining operation, a comparative study of VAM with conventional machining is undertaken to study and improve the hard turning performance. A two-dimensional (2D) finite element (FE) model is developed to understand the effect of process parameters better and to study the effect on machining performance by applying one-dimensional ultrasonic vibration to the tool. The model developed is validated with results from a previous work for continuous hard turning conditions. The effect of vibrations induced in cutting velocity direction is studied on the cutting forces and residual stresses induced on the machined workpiece. The ratio of cutting velocity to critical vibrating velocity is an important process parameter that affects the average cutting forces during hard turning using VAM. The nature of cutting force and temperature for a complete cycle of vibration is also studied. The simulation results establish that hard turning using VAM yields lower average cutting forces and more compressive residual stresses in comparison to conventional hard turning.

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