Correlation Between Acoustic Emission and Wear of Multi-Layer Ceramic Coated Carbide Tools

1997 ◽  
Vol 119 (2) ◽  
pp. 238-246 ◽  
Author(s):  
S.-S. Cho ◽  
K. Komvopoulos
Keyword(s):  
Acoustic Emission ◽  
Cutting Speed ◽  
Shear Zones ◽  
Machining Process ◽  
Contact Friction ◽  
Depth Of Cut ◽  
Near Surface ◽  
Pull Out ◽  
Ae Signal ◽  
Coated Carbide

Acoustic emission (AE) was used to monitor the machining process and tool condition during turning of AISI 4340 steel with uncoated, two-layer (TiC/Al2O3) coated, and three-layer (TiC/Al2O3/TiN) coated cemented WC-Co tools. The experiments were performed at four different feedrates and constant cutting speed and depth of cut. The variation of the AE signal with cutting time is interpreted in light of the dominant mechanisms, rates, and patterns of wear and the contact friction conditions at the tool/workpiece and tool/chip interfaces. Correlations between intrinsic frequencies and AE sources are identified by examining the root-mean-square, dominant amplitude, type, and count rate of the AE signals. It is shown that AE frequencies in the range of 50–100 kHz are primarily due to plastic deformation in the near-surface tool regions and the primary, secondary, and tertiary shear zones of the workpiece, whereas cracking leading to coating delamination and WC grain pull-out generates frequencies in the range of 170–200 kHz. The tool life estimated from the root-meansquare of the AE signal is shown to be in good agreement with that determined from measurements of the maximum wearland width on the tool nose. The obtained results demonstrate that AE is an effective technique for in-process wear monitoring and wear mechanism identification of multi-layer ceramic coated tools.

Surface Intergrity of Inconel 718 under MQL Condition

2010 ◽  
Vol 150-151 ◽  
pp. 1667-1672 ◽  
Author(s):  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
Mohd Shahir Kasim ◽  
T.K. Soon ◽  
Gusri Akhyar Ibrahim ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Machining Process ◽  
Graphical Form ◽  
Depth Of Cut ◽  
Optimum Process ◽  
Machined Surface ◽  
Coated Carbide

The purpose of this study is to investigate the effect of turning parameters on the surface integrity of Inconel 718. The turning parameters studied were cutting speed of 90, 120, 150 m/min, feed rate of 0.15, 0.25, 0.25mm/rev and depth of cut of 0.3, 0.4, 0.5 mm under minimum quantity lubricant (MQL) using coated carbide tool. surface response methodology (RSM) design of experiment using Box-Behnken approach has been employed consisting of various combination of turning parameters Surface roughness, surface topography, microstructure and the micro hardness of the machined surface were studied after the machining process. Feed rate was found to be the most significant parameter affecting the surface roughness. The optimum parameter was obtained with Ra equal to 0.243 µm at cutting speed of 150 m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm. A mathematical model for surface roughness was developed using Response Surface Methodology. The effect of turning parameters and factor interactions on surface roughness is presented in 3D graphical form, which helps in selecting the optimum process parameters to achieve the desired surface quality.

Using the Desirability Function as an Effective Tool in Target Costing Model

2015 ◽  
Vol 1115 ◽  
pp. 126-129
Author(s):  
Muataz Hazza F. Al Hazza ◽  
Mohamed Konneh ◽  
Mohammad Iqbal ◽  
Assem Hatem Taha ◽  
Muhammad H. Hasan
Keyword(s):  
High Speed ◽  
Desirability Function ◽  
Cutting Speed ◽  
Machining Process ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Target Costing ◽  
Economic Study ◽  
High Speed Turning ◽  
Coated Carbide

High speed turning (HST) is an advanced machining process that uses higher cutting speeds than those used in conventional machining. HST enables manufacturers to shorten machining times. Therefore, this approach should be followed and justified by economic study. One of the most effective tools for economic study is by developing a target-cost model to control the machining cost. The aim of this research is to develop a target costing model for high speed turning. To achieve the aim of this research, a set of experimental data was obtained in the following cutting levels: cutting speed (500-700 m/min), feed rate (1000-2000 mm/min), and depth of cut of (0.1-0.3) mm. The materials used in this research were AISI 304 stainless steel as a work piece material and coated carbide as a cutting tool. The output data was used to develop a target costing model. The desirability function has been used to optimize the model.

Performance Comparison between Dry and Nitrogen Gas Cooling when Turning Hardened Tool Steel with Coated Carbide

2015 ◽  
Vol 735 ◽  
pp. 65-69
Author(s):  
Amad Elddein Issa Elshwain ◽  
Mohamed Handawi ◽  
Norizah Redzuan ◽  
M.Y. Noordin ◽  
Denni Kurniawan
Keyword(s):  
Tool Life ◽  
Hard Turning ◽  
Removal Rate ◽  
Cutting Speed ◽  
Production Costs ◽  
Machining Process ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Nitrogen Gas ◽  
Coated Carbide

Dry machining has been successfully used in several machining applications with different cutting tools and workpiece materials due to its environmental friendliness. Dry hard turning has become an alternative machining process to grinding due to its ability to increase material removal rate, reduce production costs, and enhance of material properties. However, hard turning has several issues such as high temperatures at the tool-chip and tool-workpiece interfaces which are affecting negatively on the surface integrity of the machined parts. Using conventional cutting fluids can improve machining performance by reducing the temperature in the cutting area. However, conventional cutting fluids have some issues such as pollution, hazard on operator, high cost, and corrosion for machine tool and workpiece. All these issues related to applications of conventional cutting fluids have encouraged the researchers to look up for another alternative cooling technique in machining operation. Cooling gas has been explored as one of the alternative cooling techniques. The present paper studies the effect of applying nitrogen gas on surface roughness and tool life under different cutting parameters (cutting speed of 100, 135, and 170 m/min, feed of 0.16, 0.2, and 0.24 mm/rev, with constant depth of cut of 0.2 mm) for hard turning of stainless steel (hardness of 48 HRC) using coated carbide tools. Results showed that better surface finish and longer tool life were achieved by using nitrogen gas coolant condition compared to dry cutting.

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

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.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

The Effects of Cutting Parameters on Work-Hardening of Milling Invar 36

2015 ◽  
Vol 1089 ◽  
pp. 373-376
Author(s):  
Xing Wei Zheng ◽  
Guo Fu Ying ◽  
Yan Chen ◽  
Yu Can Fu
Keyword(s):  
Work Hardening ◽  
Lattice Distortion ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Metallographic Structure ◽  
Metallographic Observation ◽  
Coated Carbide ◽  
Carbide Insert ◽  
Axial Depth

An experiment of face milling of Invar36 was conducted by using coated carbide insert, the microhardness was tested and the metallographic structure was observed to figure out the principles of work-hardening. The results showed that the depth of work-hardening ranges from 80μm to 160μm among the parameters selected in the experiments. The degree and the depth of work-hardening were significantly affected by the axial depth of cut and feed per tooth. The degree and the depth of work-hardening showed a tendency to increase with the increase of the axial depth of cut and feed per tooth. Compared with the axial depth of cut and feed per tooth, cutting speed had less influence on the degree and depth of work-hardening. The degree and depth of work- hardening decreased slowly with the increase of cutting speed. Metallographic observation showed that work-hardening layer consisted of the thermal force influenced layer and the force influenced layer, while the amorphous metallographic structure was observed in the thermal force influenced layer, and lattice distortion was observed in the force influenced layer.

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

2021 ◽  
Vol 18 (4) ◽  
pp. 9188-9207
Author(s):  
Mahendran Samykano ◽  
J. Kananathan ◽  
K. Kadirgama ◽  
A. K. Amirruddin ◽  
D. Ramasamy ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
Alumina Nanoparticles ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Nanoparticle Concentration

The present research attempts to develop a hybrid coolant by mixing alumina nanoparticles with cellulose nanocrystal (CNC) into ethylene glycol-water (60:40) and investigate the viability of formulated hybrid nanocoolant (CNC-Al2O3-EG-Water) towards enhancing the machining behavior. The two-step method has been adapted to develop the hybrid nanocoolant at various volume concentrations (0.1, 0.5, and 0.9%). Results indicated a significant enhancement in thermal properties and tribological behaviour of the developed hybrid coolant. The thermal conductivity improved by 20-25% compared to the metal working fluid (MWF) with thermal conductivity of 0.55 W/m℃. Besides, a reduction in wear and friction coefficient was observed with the escalation in the nanoparticle concentration. The machining performance of the developed hybrid coolant was evaluated using Minimum Quantity Lubrication (MQL) in the turning of mild steel. A regression model was developed to assess the deviations in the tool flank wear and surface roughness in terms of feed, cutting speed, depth of the cut, and nanoparticle concentration using Response Surface Methodology (RSM). The mathematical modeling shows that cutting speed has the most significant impact on surface roughness and tool wear, followed by feed rate. The depth of cut does not affect surface roughness or tool wear. Surface roughness achieved 24% reduction, 39% enhancement in tool length of cut, and 33.33% improvement in tool life span. From this, the surface roughness was primarily affected by spindle cutting speed, feed rate, and then cutting depth while utilising either conventional water or composite nanofluid as a coolant. The developed hybrid coolant manifestly improved the machining behaviour.

Performance assessment of energy efficient and eco-friendly turning of Nimonic C-263: A comparative study on MQL and cryogenic machining

2021 ◽  
pp. 095440542110619
Author(s):  
Prashant S Jadhav ◽  
Chinmaya P Mohanty
Keyword(s):  
Work Environment ◽  
Manufacturing Industry ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cryogenic Machining ◽  
Machined Surface ◽  
Machining Strategies ◽  
The Impact

Nimonic C-263 is predominantly used in the manufacturing of heat susceptible intricate components in the gas turbine, aircraft, and automotive industries. Owing to its high strength, poor thermal conductivity, the superalloy is difficult to machine and causes rapid tool wear during conventional machining mode. Moreover, the unpleasant machining noise produced during machining severely disrupts the tool engineer’s concentration, thereby denying a precise and environment friendly machining operation. Hence, close dimensional accuracy, superior machined surface quality along with production economy, and pleasant work environment for the tool engineers is the need of an hour of the current manufacturing industry. To counter such issues, the present work attempts to compare and explore the machinability of two of the most popular machining strategies like minimum quantity lubrication (MQL) and cryogenic machining process during turning of Nimonic C-263 work piece in order to achieve an ideal machining environment. The machining characteristics are compared in terms of surface roughness (SR), power consumption (P), machining noise (S), nose wear (NW), and cutting forces (CF) to evaluate the impact of machining variables like cutting speed (Vc), feed (f), and depth of cut (ap) with a detailed parametric study and technical justification. Yet again, an investigation is conducted to compare both the machining strategies in terms of qualitative responses like chip morphology, total machining cost, and carbon emissions. The study revealed that cryogenic machining strategy is adequately proficient over MQL machining to deliver energy proficient and gratifying work environment for the tool engineers by reducing the cost of machining and improving their work efficiency.

An investigation on formation of burrs during milling of aluminium alloy under wet condition

2020 ◽  
pp. 095440542097201
Author(s):  
Raj Sekhar Mandal ◽  
Santanu Das ◽  
Partha Pratim Saha
Keyword(s):  
Suitable Condition ◽  
Face Milling ◽  
Machining Process ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Burr Height ◽  
Cutting Velocity ◽  
Wet Condition ◽  
Exit Edge ◽  
Coated Carbide

Undesirable burrs are created out of a machining process. The objective of the present work is to explore the suitable condition to obtain no burr, or negligible burr, around the edge of a machined product at wet condition. Face milling experiments have been carried out on blocks made of aluminum alloy (Alloy-4600M) with a single, coated-carbide inserted cutter for observing the nature of burr formation. Depth of cut has been maintained constant at 3 mm for all sets of experiments. In each experiment set, three cutting velocities (170 m/min, 237 m/min and 339 m/min) and three in-plane exit angles of 30°, 60° and 90° are provided at three different feeds of 0.08 mm/tooth, 0.1 mm/tooth and 0.12 mm/tooth. First set of experiments are done without any exit edge bevel. Similar sets of experiments are carried out with 15° and 30° exit edge bevel angles to find out the condition for minimum burr. The bevel is made of a height of 3 mm. In the present experimental investigation, a minimum burr height of as low as 3 micron is obtained at an in-plane exit angle of 30° and exit edge bevel angle of 15° under the machining condition of 339 m/min cutting velocity and 0.1 mm/tooth feed.

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