The Thermal Mechanics of Tool Wear

1966 ◽  
Vol 88 (1) ◽  
pp. 93-100 ◽  
Author(s):  
N. H. Cook ◽  
P. N. Nayak
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Empirical Evidence ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Tool Material ◽  
Simple Theories ◽  
Remarkable Agreement

Empirical evidence is presented to show that the geometry of tool wear, and the presence of built-up-edge, is strongly controlled by the chip curl. Evidence is also given which shows that some free-machining additives affect only the cutting temperature while others may affect the basic wear mechanism. Two simple theories are presented for calculating the rate of tool wear based on diffusion of tool material into the workpiece. While not conclusive, the results show remarkable agreement between predicted and measured wear based on a model wherein tool atoms jump into excess vacancies created in the chip by the plastic deformation of friction.

Evaluation of Thermal Effects in Turning Processes: Numerical and Experimental Approach

2019 ◽  
Author(s):  
Aruna Prabha Kolluri ◽  
Srinivasa Prasad Balla ◽  
Satya Prasad Paruchuru
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Tool Material ◽  
Maximum Error ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Abstract The 3D Finite element method (FEM) is an efficient tool to predict the variables in the cutting process, which is otherwise challenging to obtain with the experimental methods alone. The present study combines both experimental findings and finite element simulation outcomes to investigate the effect of tool material on output process variables, such as vibrations, cutting temperature distribution and tool wear mechanism. Machining of popular aerospace materials like Ti-6Al-4V and Al7075 turned with coated and uncoated tools are part of the investigation. The authors choose the orthogonal test, measured vibrations and cutting temperatures and used FE simulations to carry out the subsequent validations. This study includes the influence of the predicted heat flux and temperature distribution on the tool wear mechanism. The main aim of this study is to investigate the performance quality of uncoated and coated carbide tools along with its thermal aspects. Comparison of experiment and simulation outcomes shows good agreement with a maximum error of 9.02%. It has been noted that the increase of cutting temperature is proportional to its cutting speed. As the cutting speed increases, it is observed that vibration parameter and flank wear value also increases. Overall, coated carbide turning insert tool is the best method for metal turning with higher rotational speeds of the spindle.

Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 1: Effect of gradual tool wear evolution

2015 ◽  
Vol 231 (9) ◽  
pp. 1559-1574 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machined Surface ◽  
Segmented Chip ◽  
Gradual Development ◽  
Geometric Variables ◽  
On Chip

Geometric features of the segmented chip have been investigated along with the volume of material removed at a cutting speed at which tool wear is characterized by the gradual development of flank wear when cutting Ti-6Al-4V alloy. The chip geometric variables varied with an increase in the volume of material removed as the combined effect of change in tool’s geometry and increase in cutting temperature. Plastic deformation dimples were observed as periodical regions on the machined surface, a row on each undeformed surface and region on the top of the slipping surface of the segmented chip when cutting with new tool; these dimples on the undeformed surface and machined surface are elongated in the direction of chip flow. All these dimples became less with an increase in the volume of material removed and almost disappeared when the chip was removed with the worn tool at the end of its life. A model of segmented chip formation process has been proposed to satisfactorily explain the formation of the plastic deformation dimples on the undeformed surface and machined surface of the segmented chip produced with a new cutting tool and the transition of chip geometry with the evolution of tool wear.

Simulation of Machining of AISI1045 Based on Thermodynamical Constitutive Equation

2013 ◽  
Vol 333-335 ◽  
pp. 1988-1992
Author(s):  
Fang Shao ◽  
Xue Yan ◽  
Yu Ting Wang ◽  
Li Jing Zou
Keyword(s):  
Constitutive Equation ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Tool Material ◽  
Good Prediction ◽  
Wear Depth ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting

In this paper a finite element analysis (FEA) of machining for AISI1045 is presented. In particular, the thermodynamical constitutive equation (T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and tool wear depth are predicted. The comparison between the predicted and experimental cutting temperature and tool wear depth are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and tool wear depth can be achieved by the method of FEA with thermodynamical constitutive equation.

Research on the Wear Process of High Speed Cutting Ni-Based Superalloy

2014 ◽  
Vol 800-801 ◽  
pp. 102-106
Author(s):  
Jun Zhou ◽  
Ming Pu Liu ◽  
Hong Qi Sun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Wear Mechanism ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Wear Process ◽  
High Speed Cutting ◽  
Cutting Tool Wear

As the main method of high efficiency cutting Ni-based superalloy, high-speed cutting can not but intensify the cutting-tool wear for the high cutting force and cutting temperature. So, it is very necessary to study the process of cutting-tool wear and wear mechanism, especially, the effect of cutting-tool wear on the cutting force, cutting temperature and surface roughness of machined workpiece. In this paper, investigation of tool wear in high-speed cutting is proposed, the PCDTiAlN carbide insert is used in the experiment, the cutting-tool wear and the corresponding cutting force, cutting temperature and surface roughness of machined workpiece is detected. It indicates that the cutting force, cutting temperature and surface roughness of machined workpiece is changed corresponding the cutting-tool wear,the wear process of coated tool include the coated material wears and base material wears,the wear mechanism is complex. Key word: superalloy, high-speed cutting, tool wear, wear form ; .

PCBN Tool Wear Mechanism in Hard Turning Hardened Bearing Steel

2006 ◽  
Vol 315-316 ◽  
pp. 334-338 ◽  
Author(s):  
S.J. Dai ◽  
Dong Hui Wen ◽  
Ju Long Yuan
Keyword(s):  
Wear Mechanism ◽  
Hard Turning ◽  
Cutting Temperature ◽  
Tool Material ◽  
Bearing Steel ◽  
Workpiece Material ◽  
Pcbn Tool ◽  
Wear Pattern ◽  
Tool Wear Mechanism ◽  
Cutting Zone

The wear pattern and mechanism during continuous hard turning GCr15 hardened bearing steel with BZN8200 PCBN cutting tool was studied. Experimental results showed that the main wear pattern is crater wear in rake face and mechanical wear in flank face, the main wear mechanism is made-up with adhesive, oxidization and diffusive wear. The adhesive wear is generated by melt workpiece material flows with binder material of PCBN tool during initial cutting, oxidative wear is derived by cutting temperature and pressure of cutting zone when the flank wear increase after initial cutting, diffusive wear phenomenon is the absolute mechanism with the diffusive effect between workpiece and tool material in final cutting time.

Effect of High Pressure Coolant on Tool Wear Phenomenon during Machining of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 826 ◽  
pp. 93-98 ◽  
Author(s):  
Pravin Pawar ◽  
Sandip Patil ◽  
Swapnil Kekade ◽  
Swapnil Pawar ◽  
Rajkumar Singh
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Machining Process ◽  
Tool Wear Mechanism ◽  
Flank Face ◽  
Titanium Alloy Ti6al4v ◽  
High Pressure Coolant

Titanium alloys are referred to difficult-to-cut materials because of its some inferior properties like low thermal conductivity and high chemical reactivity. To improve machinability of these alloys one way is to use cutting fluids which removes the heat generated at the chip tool interface during the machining process. But coolant with low pressure and improper delivery is not able to break the vapor barrier created by high cutting temperature. The present work investigates the effect of using high pressure coolant system (50 Bar) on machinability of Ti6Al4V. The machinability was measured in terms of tool wear. The dominant tool wear mechanism was investigated by using scanning electron microscopy and energy dispersive X-ray analysis of worn out cutting tool surfaces. Abrasion wear on flank face and crater wear on the rake face was observed as a dominant tool wear mechanism. Along with this diffusion of titanium from the work surface to tool face is also confirmed.

Experimental Study on Tool Wear in NC Dry Milling Resin Sand Mold Materials

2013 ◽  
Vol 395-396 ◽  
pp. 777-781
Author(s):  
Su Yu Wang ◽  
Lin Lin Ma ◽  
Wen Jie Yang
Keyword(s):  
Tool Wear ◽  
Wear Mechanism ◽  
High Speed ◽  
Tool Material ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Sand Mold ◽  
Mold Material ◽  
Tool Wear Mechanism ◽  
Coated Cemented Carbide

Experimental research was carried out to analyze the wear patterns of several tools which include high-speed steel (HSS), coated cemented carbide and ceramic tools, and to study the tool wear mechanism in milling resin sand mold materials. The main wear mechanism is abrasive wear and the dominant tool failure mode is flank wear. Different cutting parameters have different influence to the tool wear. In addition, it is essential to select suitable tool material with appropriate hardness. In this paper, the experiment results are contributive to choose proper cutting tool materials and parameters in milling resin sand mold material.

scholarly journals Tool wear by dissolution during machining of alloy 718 and Waspaloy: a comparative study using diffusion couples

2019 ◽  
Vol 106 (3-4) ◽  
pp. 1431-1440
Author(s):  
Philipp Hoier ◽  
Kumar Babu Surreddi ◽  
Uta Klement
Keyword(s):  
Tool Wear ◽  
Test Temperature ◽  
Wear Mechanisms ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Tool Material ◽  
Alloy 718 ◽  
Diffusion Couples ◽  
Wear Rates ◽  
Static Conditions

AbstractThe wear of metal cutting tools is known to take place by the combined and simultaneous effects of several wear mechanisms. Knowledge of the relative contribution of the individual wear mechanisms is required to understand and predict the tool wear during cutting different workpiece materials and alloys. It has been shown previously that machining two heat resistant superalloys, alloy 718 and Waspaloy, leads to distinctively different tool wears. Even though the subject has been addressed in various studies, there are still open questions regarding the underlying reasons for the differing tool wear rates. In particular, the relative contributions of diffusion/dissolution when machining the two alloys have not been addressed so far. Therefore, a qualitative comparison of the chemical interaction between the tool material and the two superalloys was made by using diffusion couple tests. The aim was to mimic the high temperatures and intimate contact between workpiece and tool material at the tool rake and flank faces during cutting under controlled and static conditions. The obtained results suggest that it is unlikely that differences in flank wear rate when machining the two superalloys are caused by significantly varying magnitudes of tool atoms dissolving into the respective workpiece. Analysis of the tool/superalloy interfaces in the diffusion couples revealed diffusion-affected zones of similar size for both tested superalloys. Increasing test temperature led to enhanced interdiffusion which suggests an increase in tool wear by diffusion/dissolution for higher cutting temperature. For alloy 718, the higher test temperature also led to depletion of carbon together with formation of tungsten within the tool in close vicinity to the interface with the superalloy.

Simulation of Machining of AISI1045 Based on Thermodynamics

2015 ◽  
Vol 751 ◽  
pp. 273-277
Author(s):  
Fang Shao ◽  
Li Hua Xiao ◽  
Yu Ting Wang
Keyword(s):  
Constitutive Equation ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Tool Material ◽  
Good Prediction ◽  
Wear Depth ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting

In this paper a finite element analysis (FEA) of machining for AISI1045 is presented. In particular, the thermodynamical constitutive equation (T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and tool wear depth are predicted. The comparison between the predicted and experimental cutting temperature and tool wear depth are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and tool wear depth can be achieved by the method of FEA with thermodynamical constitutive equation.

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