Fatigue Fracture Investigation of Cemented Carbide Tools in Gear Hobbing, Part 1: FEM Modeling of Fly Hobbing and Computational Interpretation of Experimental Results

2002 ◽  
Vol 124 (4) ◽  
pp. 784-791 ◽  
Author(s):  
A. Antoniadis ◽  
N. Vidakis ◽  
N. Bilalis
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Complex Geometry ◽  
High Speed Steel ◽  
Cutting Performance ◽  
Cutting Process ◽  
Cemented Carbide ◽  
Fem Modeling ◽  
Gear Hobbing ◽  
Cemented Carbide Tools

Gear hobbing is a highly utilized flexible manufacturing process for massive production of external gears. However, the complex geometry of cutting hobs is responsible for the almost exclusive utilization of high-speed steel (HSS) as cutting tool material. The limited cutting performance of HSS, even coated HSS, restricts the application of high cutting speeds and restricts the full exploitation of modern CNC hobbing machine tools. The application of cemented carbide tools was considered as a potential alternative to modern production requirements. In former investigations an experimental variation of gear hobbing, the so-called fly hobbing was applied, in order to specify the cutting performance of cemented carbide tools in gear production. These thorough experiments indicated that cracks, which were not expected, might occur in specific cutting cases, leading to the early failure of the entire cutting tool. In order to interpret computationally the reasons for these failures, an FEM simulation of the cutting process was developed, supported by advanced software tools able to determine the chip formation and the cutting forces during gear hobbing. The computational results explain sufficiently the failure mechanisms and they are quite in line with the experimental findings. The first part of this paper applies the verified parametric FEM model for various cutting cases, indicating the most risky cutting teeth with respect to their fatigue danger. In a step forward, the second part of the paper illustrates the effect of various technological and geometric parameters to the expected tool life. Therefore, the optimization of the cutting process is enabled, through the proper selection of cutting parameters, which can eliminate the failure danger of cemented carbide cutting tools, thus achieving satisfactory cost effectiveness.

Fatigue behavior of two notched cutting tool materials – High speed steel and cemented carbide

2020 ◽  
Vol 62 (3) ◽  
pp. 265-270
Author(s):  
Zainul Huda ◽  
Muhammad Hani Ajani ◽  
Muhammad Saad Ahmed
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Fatigue Behavior ◽  
High Speed Steel ◽  
Cemented Carbide ◽  
Tool Materials ◽  
Cutting Tool Materials

Fatigue behavior of two notched cutting tool materials – high speed steel and cemented carbide

2020 ◽  
Vol 62 (2) ◽  
pp. 123-128
Author(s):  
Zainul Huda ◽  
Muhammad Hani Ajani ◽  
Muhammad Saad Ahmed
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Fatigue Behavior ◽  
High Speed Steel ◽  
Cemented Carbide ◽  
Tool Materials ◽  
Cutting Tool Materials

The Current Status and Future Directions of Cutting Tool Materials

2014 ◽  
Vol 529 ◽  
pp. 247-250
Author(s):  
Ying Peng Dai ◽  
Shu Qiong Xu
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
High Speed Steel ◽  
Cemented Carbide ◽  
Current Status ◽  
Hard Material ◽  
Future Directions ◽  
Tool Materials ◽  
Cutting Tool Materials

This paper introduces the performance and application of various cutter materials including high-speed steel, cemented carbide, ceramic and super-hard material. The current status and prospect in the tool materials are discussed.

Gear Hobbing Cutting Process Simulation and Tool Wear Prediction Models

2001 ◽  
Vol 124 (1) ◽  
pp. 42-51 ◽  
Author(s):  
K.-D. Bouzakis ◽  
S. Kombogiannis ◽  
A. Antoniadis ◽  
N. Vidakis
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Prediction Models ◽  
Numerical Models ◽  
High Speed Steel ◽  
Cutting Process ◽  
Wear Prediction ◽  
Tool Wear Prediction ◽  
Gear Hobbing ◽  
The Individual

Gear hobbing is an efficient method to manufacture high quality and performance toothed wheels, although it is associated with complicated process kinematics, chip formation and tool wear mechanisms. The variant cutting contribution of each hob tooth to the gear gaps formation might lead to an uneven wear distribution on the successive cutting teeth and to an overall poor tool utilization. To study quantitatively the tool wear progress in gear hobbing, experimental-analytical methods have been established. Gear hobbing experiments and sophisticated numerical models are used to simulate the cutting process and to correlate the undeformed chip geometry and other process parameters to the expected tool wear. Herewith the wear development on the individual hob teeth can be predicted and the cutting process optimized, among others, through appropriate tool tangential shifts, in order to obtain a uniform wear distribution on the hob teeth. To determine the constants of the equations used in the tool wear calculations, fly hobbing experiments were conducted. Hereby, it was necessary to modify the fly hobbing kinematics, applying instead of a continuous tangential feed, a continuous axial one. The experimental data with uncoated and coated high speed steel (HSS) tools were evaluated, and correlated to analytical ones, elaborated with the aid of the numerical simulation of gear hobbing. By means of the procedures described in this paper, tool wear prediction as well as the optimization of various magnitudes, as the hob tangential shift parameters can be carried out.

scholarly journals Peculiarities Regarding the Smooth Entrance of the Drill in Cutting When Processing Steel

2020 ◽  
Vol 21 (2) ◽  
pp. 83-88
Keyword(s):  
Axial Force ◽  
High Speed ◽  
Cutting Tool ◽  
Active Element ◽  
High Speed Steel ◽  
Cutting Process ◽  
Small Range ◽  
Helical Spring ◽  
The Way

Metal drilling is one of the most common methods of obtaining cylindrical bores. At the same time, the drill is the cutting tool that cuts in the most difficult conditions and consequently any measure that leads to the improvement of the cutting process is useful. The smooth entrance in the cutting is a way to increase the durability of the drill and consequently specific devices have been developed. One of these devices is shown in this paper and previous research shows the effectiveness of its use in drilling. The analysis of the device shows that it is used for cutting 41MoC11 and C45 steels with high speed steel drills, which are in a small range of sizes. The active element of the device is identified, a helical spring working for compression, and by calculating the respective axial force of the torque, is determined exactly the range of diameters of the drills that can cut effectively. At the same time is analyzed the way of enlarging the range of drills used with the device for smooth entrance in cutting, by introducing a second spring, concentric with the first, and which works simultaneously with it, thus the device was reengineered.

Development of an Alternative Approach for Cutting Force Determination in Broaching

2019 ◽  
Author(s):  
Thomas Bergs ◽  
Benjamin Döbbeler ◽  
Tobias Seelbach ◽  
Martin Seimann ◽  
Fritz Klocke
Keyword(s):  
Manufacturing Process ◽  
High Speed ◽  
Cutting Tool ◽  
Tool Material ◽  
High Speed Steel ◽  
Tool Design ◽  
Cemented Carbide ◽  
Tool Geometry ◽  
Alternative Approach ◽  
Cutting Speeds

Abstract Fir tree slots in turbine discs are used as an attachment between the disc and the blades. To a great extend, these slots are manufactured by broaching. Currently, the used cutting tool material is High Speed Steel (HSS). Due to its low high temperature stability, the manufacturing process is limited to low cutting speeds (vc = 2–5 m/min) and presents, therefore, a bottleneck in the turbine manufacturing process. To increase the productivity, cemented carbide can be used as cutting tool material with cutting speeds up to five times higher than those used for HSS. Due to the high safety demands, the broaching process requires extensive process design to ensure a high process reliability. For the tool design, profound knowledge of the mechanical loads is mandatory due to its major effect on the manufactured part. Empirical research to investigate the actual mechanical load is time-consuming and expensive due to high tool costs, especially of cemented carbide broaches, and the high amount of possible tool geometry combinations. In this paper, an alternative approach to determine the cutting forces is presented. Grooving experiments were conducted in order to reproduce the engagement conditions from the broaching process. If the transferability of this approach can be shown, the amount of broaching tools as well as the availability of a broaching machine tool for the design of new broaching tools can be decrease dramatically. This would result in a reduction of tool design time and an increase in productivity for tool manufacturers.

scholarly journals Cutting performance of deep cryogenic treated and nitrided HSS cutting tool inserts

2019 ◽  
Vol 13 (3) ◽  
pp. 213-217
Author(s):  
Sanja Šolić ◽  
Zdravko Schauperl ◽  
Vlado Tropša
Keyword(s):  
Wear Resistance ◽  
High Speed ◽  
Cutting Tool ◽  
Cryogenic Treatment ◽  
Single Point ◽  
Cutting Tools ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Cutting Performance ◽  
Deep Cryogenic Treatment

High speed steel (HSS) is a very important industrial tool material and has been constantly improved for different wear resistance applications and cutting tools, i.e. drills, milling cutters, hobs and for the cutting tools in which the economical cutting speed is too low for choosing the carbide tools. The properties of HSS depend significantly on the parameters of the conducted heat treatment. In this paper, the influence of deep cryogenic treatment in combination with nitriding of metallurgical powder metallurgy HSS on the wear resistance was measured. Additionally, the cutting performance in a single point cutting tool machinability test at the configuration of the dry low-speed turning of steel was investigated. The results showed that deep cryogenic treatment itself, and in combination with nitriding, resulted in the reduction of the wear rate. The results of the single point cutting tool machinability test showed that deep cryogenic treated and nitrided HSS inserts performed worse than the classically heat-treated inserts and deep cryogenic treated HSS inserts exhibited approximately the same flank wear as the nitrided ones.

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