On the Wear Mechanisms and Cutting Performance of Silicon Carbide Whisker-Reinforced Alumina

1992 ◽  
Vol 114 (3) ◽  
pp. 301-308 ◽  
Author(s):  
A. R. Thangaraj ◽  
K. J. Weinmann
Keyword(s):  
Silicon Carbide ◽  
Wear Mechanisms ◽  
Flank Wear ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Tool Failure ◽  
Silicon Carbide Whisker ◽  
Nickel Based Superalloy ◽  
Notch Wear ◽  
Cutting Speeds

The objective of this research was to study the types of wear suffered by silicon carbide whisker-reinforced aluminum oxide inserts in the machining of Inconel 718. Further, it was desired to study the effects of tool wear and cutting conditions on cutting forces, workpiece dimensional accuracy, and surface finish. Machining tests were conducted using 12.7 mm diameter round inserts at cutting speeds ranging from 6.0 to 13.0 m/s. The feed rates ranged from 0.13 to 0.51 mm/rev and two depths of cut of 0.76 and 1.27 mm were used. Tool failure in the cutting of the relatively soft (220 HB) nickel-based superalloy was due to excessive wear. Flank wear played a larger role at the lower speeds, but depth-of-cut notch wear was significant at the higher speeds. Abrasion, adhesion, and chipping were found to be the dominant wear mechanisms. The results of this study are presented and discussed in this paper.

Performance of CBN and PCBN Tools on the Machining of Hard AISI 440C Martensitic Stainless Steel

2011 ◽  
Vol 264-265 ◽  
pp. 1137-1147 ◽  
Author(s):  
S. Thamizhmanii ◽  
Rosli Ahmad ◽  
S. Hasan
Keyword(s):  
Stainless Steel ◽  
Cutting Forces ◽  
Flank Wear ◽  
Martensitic Stainless Steel ◽  
Dimensional Accuracy ◽  
Hard Metal ◽  
Depth Of Cut ◽  
Tool Surface ◽  
Pcbn Tools ◽  
Cutting Speeds

In this study, flank wear on CBN and PCBN tools due to cutting forces were studied. Turning tests were carried using cutting speeds of 100, 125, 150, 175 and 200 m/min with feed rates of 0.10, 0.20 and 0.30 mm/rev and constant depth of cut. The performances of tools were evaluated based on the flank wear and cutting forces. There is clear relationship between flank wear and cutting forces while turning hard martensitic stainless steel by CBN and PCBN tools. Low cutting forces leads to low flank wear formation and low cutting forces provided good dimensional accuracy of the work material including low surface roughness. Flank wear formation was mostly caused by abrasion and adhesion. The built up edges formed reduced the cutting forces and also causes the heat generated at tool tip and work interface. High cutting forces are identified and this may be due to heat and flank wear combinations. Flank and crater wear on the rake face and hard metal deposition due to diffusion of metals on the cutting tool surface are the damages occurred during process.

Analysis of Tool Wear: Part II: Applications of Flank Wear Models

1970 ◽  
Vol 92 (1) ◽  
pp. 109-114 ◽  
Author(s):  
A. Bhattacharyya ◽  
A. Ghosh ◽  
Inyong Ham
Keyword(s):  
Tool Wear ◽  
Critical Points ◽  
Quantitative Assessment ◽  
Inflection Point ◽  
Flank Wear ◽  
Cemented Carbides ◽  
Temperature Sensitive ◽  
Tool Failure ◽  
Cutting Speeds ◽  
Asme Paper

For machining with cemented carbides and ceramics, a quantitative assessment of tool failure at the flank for establishing “limit criterion” is necessary. The arbitrarily chosen flank wear limit for all cutting speeds is not valid at higher cutting speeds because of the earlier appearance of the “inflection point” which is often taken as criterion of flank-failure. In this paper, proceeding from the basic physical model of flank wear described in Part I of the paper (ASME Paper No. 68—WA/Prod-5), tool-life relations in the form of Taylor’s equations have been theoretically developed, the parameters of which have been compared with, experimental results. Further, the critical points of inflexion where the flank-wear characteristic enters temperature sensitive region resulting in accelerated wear have been uniquely defined. The location of these critical points have also been verified experimentally.

Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 2: Effect of tool failure modes

2015 ◽  
Vol 231 (9) ◽  
pp. 1575-1586 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Machined Surface ◽  
Tool Failure ◽  
Geometric Ratio ◽  
Cutting Speeds

Variation in the geometric and surface features of segmented chips with an increase in the volume of material removed and tool wear has been investigated at cutting speeds of 150 and 220 m/min at which the cutting tools fail due to gradual flank wear and plastic deformation of the cutting edge, respectively. Among the investigated geometric variables of the segmented chips, slipping angle, undeformed surface length, segment spacing, degree of segmentation and chip width showed the different variation trends with an increase in the volume of material removed or flank wear width, and achieved different values when tool failed at different cutting speeds. However, the chip geometric ratio showed a similar variation trend with an increase in the volume of material removed and flank wear width, and achieved the similar value at the end of tool lives at cutting speeds of both 150 and 220 m/min regardless of the different tool failure modes. Plastic deformation of the tool cutting edge results in severe damage on the machined surface of the chip and significant compression deformation on the undeformed surface of the chip.

A Surface Roughness Study for Machining of Udimet500 Superalloy, through Statistical Analysis of Influential Parameters

2012 ◽  
Vol 445 ◽  
pp. 923-928
Author(s):  
Es Ghadiri Zahrani ◽  
H. Soleimanimehr ◽  
Amir Heidari Shahmaleki ◽  
D. Zamani
Keyword(s):  
Surface Roughness ◽  
High Surface ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Manufacturing Companies ◽  
Paper Surface ◽  
Nickel Based Superalloy ◽  
Manufacturing Methods ◽  
Influential Parameters ◽  
Cutting Speeds

Superalloy is an alloy that has been developed to be used in processes with high thermal and mechanical stresses and also preserving high surface stabilities. Because of the increase in temperature and wearing of tool tip (even in low cutting speeds), machining of these materials has not developed considerably. Increase in demand for machining of these materials equally increases the need for investigating their manufacturing methods. For this reason, optimal machining of superalloys is very important and is under great investigations. The most important parameter for manufacturing companies is surface roughness. In the present paper, surface roughness of Udimet500 superalloy which is a nickel-based superalloy is investigated. Based on regression analysis, the most influential parameters to surface roughness are obtained and a relation for the roughness with respect to depth of cut, cutting speed, feed rate and lubricant type (CO2, Z1 or dry) is derived.

Wear mechanisms of coated mixed-ceramic tools during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (1) ◽  
pp. 183-193 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Feed Rate ◽  
Wear Mechanisms ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Protective Layer ◽  
Depth Of Cut ◽  
Work Piece ◽  
Die Steel ◽  
Mixed Ceramic

The present study aims to investigate the wear mechanisms of a TiN-coated mixed ceramic tool prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed are abrasion wear at low cutting speed, low feed rate, and highest work piece hardness; formation of protective layer and built-up edge (BUE) resulting from tribochemical reactions between constituents of tool and work piece material at moderate speed. High temperature accompanied by high cutting speed resulted in the removal of the protective layer and suppressed the BUE formation. Hard carbide particles of work material at a higher feed rate severely gouged the tool flank land. Chipping and brittle fractures were observed at very low and high depth of cut. Adhesion of work piece material followed by plastic deformation and notching was clearly visible at low work piece hardness. The influence of cutting speed, feed rate, depth of cut, and work piece hardness on the progressive tool flank wear, and flank wear rate (VBr-μm/km) in the steady wear region was also analysed.

Wear Rate of CBN Cutting Tool in Hard Turning of 100Cr6 Bearing Steel

2013 ◽  
Vol 581 ◽  
pp. 50-54
Author(s):  
László Ráczkövi
Keyword(s):  
Wear Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Significant Proportion ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Average Wear ◽  
Cutting Speeds

The examination of wear and tool life of CBN cutting tools which are used for hard turning is a emphasized research theme, since the significant proportion of cost of machining associated with cutting tool. In this article we examined the wear of low CBN content cutting tool in case of hard turning of 100Cr6 bearing steel (HRC=62±2). The experiments were carried out with constant depth of cut and feed rate at three different cutting speeds. The flank wear of CBN inserts were measured after predetermined number of passes. The measured flank wear values were described as a function of cutting time and the calculated wear rate as a function of flank wear.The average wear rate were shown at three different cutting speeds.

The Research on Milling Force in High-Speed Milling Nickel-Based Superalloy of Inconel 718

2013 ◽  
Vol 395-396 ◽  
pp. 1031-1034
Author(s):  
Can Zhao ◽  
Yu Bo Liu
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Milling Force ◽  
High Speed Milling ◽  
Nickel Based Superalloy ◽  
Cutting Speeds

This paper makes an experiment in high-speed milling of Inconel 718. Cutting tests were performed using round and ceramic tools, at feeds from 0.06 to 0.14 mm/tooth, Axial Depth of Cut from0.5 to 1.5mm,and cutting speeds ranging from 500 to 1037 m/min. The behaviour of the cutting forces during machining was then measure. The results show that cutting force increases first and then decreases with the increase of feed per tooth, the tool chipping and groove wear were found with the increase of axial cutting depth, and cutting force is increased; the increase in cutting force with the cutting speed increases, when the cutting speed reaches a critical speed, the cutting force as the cutting speed increases began to decline.

Wear mechanisms of TiN-coated CBN tool during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (4) ◽  
pp. 553-566 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Wear Rate ◽  
Feed Rate ◽  
Wear Mechanisms ◽  
High Speed ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Die Steel

The aim of the present investigation was to identify the wear mechanisms of TiN-coated CBN tools prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed were abrasion wear at low cutting speed, low feed rate, and high workpiece hardness; formation of a transferred layer resulting from tribochemical reactions between constituents of the tool and workpiece material at high speed; and the formation of built-up edges at moderate cutting speed. Hard carbide particles of the work material at higher feed rate severely abraded the tool flank land, resulting in shallow grooves due to the detachment of CBN grains. At greater depth of cut, the built-up edges and transferred layer reduced friction and tool wear. Excessive adhesion of workpiece material followed by plastic deformation and notching were clearly visible at low workpiece hardness (47 HRC). The influence of cutting speed, feed rate, depth of cut, and workpiece hardness on the progressive tool flank wear, i.e. flank wear rate (VBr, μm/mm) in the steady wear region, was also analysed. The flank wear rate was observed to decrease with increase in cutting speed, depth of cut, and workpiece hardness, but after an initial decrease it increased with increase in feed rate.

Research on the Cutting Property of Ceramic Tool Cutting Nickel Based Superalloy GH4169

2014 ◽  
Vol 800-801 ◽  
pp. 87-91
Author(s):  
Yu Bo Liu ◽  
Yong De Zhang ◽  
Can Zhao
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Ceramic Tool ◽  
Ceramic Cutting Tool ◽  
Nickel Based Superalloy ◽  
Tool Wear Mechanism ◽  
Tool Cutting ◽  
Notch Wear

This paper will use the Al2O3-SiCw whisker toughening ceramic tool WG300 and Si3N4-Al2O3 (Sialon) SX9 ceramic tool cutting performance test.Study on different cutting speed, ceramic cutting tool in machining nickel based high-temperature alloy tool life and tool wear mechanism, and analysis of the wear form under different cutting parameters. The test results show that: with the increase of the cutting speed, WG300 and SX9 two kinds of tool durability showed a downward trend, the value of VB is higher than that of Al2O3-SiCw whisker reinforced ceramic cutting tool flank wear of Sialon ceramic cutting tool, but its notch wear value VN is far less than Al2O3-SiCw whisker reinforced ceramic cutting tool,the main failure form of WG300 notch wear, the main failure form of SX9 for the flank wear.

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