Basic Investigation of Tool Wear

1963 ◽  
Vol 85 (1) ◽  
pp. 33-37 ◽  
Author(s):  
H. Takeyama ◽  
R. Murata
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Condition ◽  
Rate Process ◽  
Mechanical Abrasion ◽  
Fundamental Investigation ◽  
First Approximation ◽  
Basic Investigation

This paper treats a fundamental investigation of tool wear and tool life mainly from the viewpoint of flank wear. The result reveals that the mechanism of tool wear in turning can be classified into two basic types: The mechanical abrasion which is directly proportional to the cutting distance and independent of the temperature; and the other is, so to speak, a physicochemical type which is considered to be a rate process closely associated with the temperature, of course. Although it depends upon the cutting condition which type of wear plays a more important role, the latter is predominant under usual conditions. According to the analyses and the experimental results, it has been found out that the tool life from the standpoint of flank wear can be predicted to a first approximation by the initial cutting temperature.

OPTIMUM FLANK WEAR OF TiAlN-COATED TOOL: TOWARD PRODUCTIVE ROUGH CUTTING OF INCONEL 625

2019 ◽  
Vol 26 (08) ◽  
pp. 1850230
Author(s):  
A. AKHAVAN FARID ◽  
MOHAMMAD LOTFI ◽  
M. JAHANBAKHSH
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Optimum Cutting

Long tool life and high material removal rate (MRR) are the two essential requirements in rough cutting of materials. The rapid rate of the flank wear propagation in machining of nickel-based superalloys has induced the utilization of low cutting parameters when the goal was set to maximize the tool life based on the machining time or cutting length. However, this method may not provide an effective rate for the material being cut. This work presents two mathematical models to find the optimum cutting parameters results for the minimum flank wear and maximum MRR. Experimental tests were carried out based on the central composite design (CCD) in rough cutting of Inconel 625 by using TiAlN-coated insert. Maximum flank wear was measured to determine the tool wear propagation. The wear mechanisms which contribute in the tool wear were analyzed by using scanning electron microscope (SEM) to evaluate the effects of cutting parameters on the flank wear propagation. The results showed that cutting speed and depth of cut had the most significant effect on the tool wear. However, optimum cutting condition was achieved by reducing the cutting speed when feed rate and depth of cut maintained at the highest level. This was associated to the interaction of cutting speed and depth of cut, and predominant of abrasion and notching at their highest levels, respectively.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

The Analysis of Tool Wear in Milling CFRP with Different Diamond Coated Tool

2015 ◽  
Vol 667 ◽  
pp. 231-236 ◽  
Author(s):  
Xiao Fan Yang ◽  
You Sheng Li ◽  
Guo Hong Yan ◽  
Ju Dong Liu ◽  
Dong Min Yu
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Milling Process ◽  
Cutting Condition ◽  
End Mill ◽  
Reinforced Plastics ◽  
Right Hand ◽  
Coated Tool ◽  
New Type ◽  
Fiber Reinforced Plastics

Carbon fiber-reinforced plastics (CFRP) are typical difficult-to-machine materials, which is easy to produce many defects such as burrs, dilacerations, layering in milling process. And selecting the appropriate cutting tool has become the key to machining CFRP with high quality and efficiency. In the paper, the machining principle of milling CFRP with new type end mill was analyzed. The diamond coating of general right-hand end mill, cross-flute router and fine-cross-nick router were used to cutting CFRP under the same cutting condition. Through the comparative analysis of the workpiece’s surface quality and tool wear, it concluded that: compared with right-hand diamond coated end mill, cross-flute diamond coated router or fine-cross-nick diamond coated router could effectively suppress the appearance of burrs and dilacerations; abnormal coating peeling appeared in the flank face of right-hand diamond coated end mill, forming the boundary wear, which accelerated wear failure; the flank wear of diamond coated cross-flute router and fine-cross-nick router were both abrasive wear. Due to having more cutting edge than cross-flute router in cutting process, the flank wear of fine-cross-nick router was slower, and the tool life was longer. So it was more suitable for cutting CFRP.

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

Study on Tool Life and Tool Wear Mechanisms in Dry Cutting Pure Iron

2013 ◽  
Vol 770 ◽  
pp. 74-77 ◽  
Author(s):  
Jin Xing Kong ◽  
Liang Li ◽  
Dong Ming Xu ◽  
Ning He
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Pure Iron ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Condition ◽  
High Plasticity ◽  
Dry Cutting ◽  
Tool Wear Mechanisms

Pure iron is a kind of high plasticity and toughness material. In the process of cutting pure iron, the tool wear is very serious. In this paper, three kinds of cutting tools KC5010, K313 and 1105 are used in the cutting pure iron process and the tool wear tests in dry cutting condition with different cutting parameters have been carried out. According to the results, the tool wear mechanisms and tool life of three kinds of cutting tools have been compared and analyzed. It is concluded that the tool life of K313 is better than KC5010 and 1105 and the three kinds of tool mechanisms are primarily adhesion wear, diffusion wear and oxidation wear.

Tool Wear Behavior in Turning Inconel 718 with Coated Inserts

2012 ◽  
Vol 499 ◽  
pp. 348-352 ◽  
Author(s):  
Xiao Li Zhu ◽  
Song Zhang ◽  
X.L. Xu ◽  
H.G. Lv
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Cutting Condition ◽  
Tool Holder ◽  
Final Failure ◽  
Coated Carbide

In the present study, an experimental investigation has been carried out in an attempt to monitor tool wear progress in turning Inconel 718 with coated carbide inserts under the wet cutting condition. First, each experimental test was conducted with a new cutting edge and the turning process was stopped at a certain interval of time. Secondly, the indexable insert was removed from the tool holder and the flank wear of the insert was measured using a three-dimensional digital microscopy (VHX-600E); and then the insert was clamped into the tool holder for the next turning experiment. The final failure of tool wear surfaces were examined under a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectrometer (EDS). It is indicated that significant flank wear was the predominant failure mode, and the abrasive, adhesive and oxidation wear were the most dominant wear mechanisms which directly control the deterioration and final failure of the cutting tools.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Chaotic Tool Wear During Machining of Titanium Metal Matrix Composite (TiMMCs)

2014 ◽  
Author(s):  
Xuan-Truong Duong ◽  
Marek Balazinski ◽  
René Mayer
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Tool Life ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Titanium Metal

The initial tool wear during machining of titanium metal matrix composite (TiMMCs) is the result of several wear mechanisms: tool layer damage, friction - tribological wear, adhesion, diffusion and brace wear. This phenomenon occurs at the first instant and extends to only ten seconds at most. In this case the adhesive wear is the most important mechanism while the brace wear is considered as a resistance wear layer at the beginning of the steady wear period. In this paper, the effect of the initial tool wear and initial cutting conditions on tool wear progression and tool life is investigated. We proposed herein a new mathematical model based on the scatter wear and Lyapunov exponent to study quantitatively the “chaotic tool wear”. The Chaos theory, which has proved efficient in explaining how something changes in time, was used to demonstrate the dependence of the tool life on the initial cutting conditions and thus contribute to a better understanding of the influence of the initial cutting condition on the tool life. Based on the chaotic tool wear model, the scatter wear dimension and Lyapunov exponents were found to be positive in all case of the initial cutting conditions such as initial speed, feed rate and depth of cut. The initial cutting speed appears however to have the most significant impact on tool life. In particular, the mathematical model was successfully applied to the case of machining TiMMCs. It was clearly shown that changing the initial cutting speed by 20 m/min for the first two seconds of machining instead of keeping it constant at 60 m/min during the whole cutting process leads to an increase in the tool life (up to 24%).

Effect of Pressure and Nozzle Angle of Minimal Quantity Lubrication on Cutting Temperature and Tool Wear in Turning

2014 ◽  
Vol 695 ◽  
pp. 676-679 ◽  
Author(s):  
Abdullah Yassin ◽  
Chong Yaw Teo
Keyword(s):  
Tool Wear ◽  
Palm Oil ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Manufacturing Cost ◽  
Dry Cutting ◽  
Optimum Cutting ◽  
Minimal Quantity Lubrication ◽  
Minimal Quantity

This paper presents an experimental investigation on effects of pressure and nozzle angle of minimal quantity lubrication (MQL) on cutting temperature and flank wear in turning. In manufacturing industries, there are always demands for the optimum cutting conditions for the most economical manufacturing cost. Hence, reduction in tool wear is essential for less expenditure with the knowledge of optimum cutting conditions of MQL. MQL, also known as near dry machining, has been acknowledged as an effective cooling technique in machining by applying vegetable oils in replacing the conventional flooding method due to environmental issues. By varying the operating pressures and nozzle angle with respect to the cutting zone, cutting temperature and flank wear are measured using a calibrated tool work thermocouple and SPG video microscope. Comparison was made between dry cutting, water mist cooling and MQL method with palm oil. Results showed that MQL with palm oil exhibits best cooling efficiency at 5 bar pressure and nozzle angle of 20o with reduction of 35% in tool wear and 23% in cutting temperature at higher cutting speeds.

Predictive Models for Flank Wear in Near Dry Machining

2005 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dominant Factor ◽  
Force Model ◽  
Temperature Model ◽  
Dry Machining ◽  
Cutting Force Model ◽  
Wear Model

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

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