Study of a High Performance AFM Probe-Based Microscribing Process

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
Keith Bourne ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
Tool Wear ◽  
High Performance ◽  
Cutting Speed ◽  
Rake Angle ◽  
Motion Platform ◽  
High Cutting Speed ◽  
Working Volume ◽  
Afm Probe ◽  
Tool Motion ◽  
Five Axis

In this paper, a mechanical microscribing process is described that combines AFM probe-based microscribing with a five-axis microscale machine tool motion platform in order to achieve high scribing speeds, a large working volume, and the capability of cutting curvilinear patterns of grooves. An experiment is described that demonstrates groove formation, groove shape, and tool wear when long grooves are formed using multiple tool passes. A second more systematic experiment is described in which short-distance single-pass cutting tests were used to explore the effects of cutting speed, nominal tool load, and AFM probe mounting angle on groove geometry, tool wear, effective rake angle, and chip formation. Lastly, an experiment is described in which a long curvilinear groove is cut. It is shown that the most well-formed grooves were cut and acceptable tool wear was achieved, when using a high cutting speed, high nominal tool load, and low probe mounting angle. The capability of cutting grooves as long at 82 mm but with depths of only a few hundred nanometers, using a single tool pass at cutting speeds as high at 25 mm/min is demonstrated.

Performance Evaluation of PVD and CVD Coated Inserts during End Milling with DRY and MQL Condition

2017 ◽  
Vol 867 ◽  
pp. 165-170
Author(s):  
Isha Srivastava ◽  
Ajay Batish
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
High Cutting Speed ◽  
Cutting Operation ◽  
En 31

The aim of this study were to evaluate the performance of PVD (TiAlN+TiN) and CVD (TiCN+Al2O3+TiN) coated inserts in end milling of EN–31 hardened die steel of 43±1 HRC during dry and MQL (Minimum quantity lubrication) machining. The experiments were conducted at a fixed feed rate, depth of cut and varying cutting speed to measure the effect of cutting speed on cutting force and tool wear of CVD and PVD-coated inserts. The performance of CVD and PVD-coated inserts under dry and MQL condition by measuring the tool wear and cutting force were compared. During cutting operation, it was noticed that PVD inserts provide less cutting force and tool wear as compared to the CVD inserts under both dry as well as the MQL condition because PVD inserts have a thin insert coating and CVD inserts have a thick insert coating, but PVD inserts experience catastrophic failure during cutting operation whereas CVD inserts have a capability for continuous machining under different machining. Tool wear has measured by SEM analysis. The result shows that MQL machining provides the optimum results as compared to the dry condition. MQL machining has the ability to work under high cutting speed. As the cutting speed increases the performance of dry machining was decreased, but in MQL machining, the performance of the inserts was increased with increases of cutting speed. MQL machining generates less cutting force on the cutting zone and reduces the tool wear which further increase the tool life.

Tool Wear of Polycrystalline Cubic Boron Nitride Compact Tools in Cutting Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 724-728 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Boron Nitride ◽  
Tool Wear ◽  
Tool Life ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Cbn Tool ◽  
High Cutting Speed

Using polycrystalline cubic boron nitride compact (cBN) tools, which have different cBN contents and cBN particle sizes, the influences of both the cBN content and the cBN particle size on tool wear in turning of hardened steel at various cutting speeds was experimentally investigated. Three types of cBN tools (a cBN content of 45-55% and 75%, and a cBN particle size of 0.5 μm and 5 μm, respectively) were tested. Furthermore, three kinds of chamfered and honed cutting edges were also used. The main results obtained are as follows: (1) In the case of the cBN tools with the same cBN particle size of 5.0 μm, the tool life of the cBN tool with a cBN content of 75% was longer than that of the cBN tool with a cBN content of 45% at low cutting speed. However, at high cutting speed, the tool life of the cBN tool with a cBN content of 75% was shorter. (2) The tool life of the cBN tool with both a cBN content of 55% and a cBN particle size of 0.5 μm was the longest. (3) The tool wear of cBN tools decreased with a decrease in chamfer width.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

Effect of Cryogenic Minimum Quantity Lubrication (CMQL) on Cutting Temperature and Tool Wear in High-Speed End Milling of Titanium Alloys

2010 ◽  
Vol 34-35 ◽  
pp. 1816-1821 ◽  
Author(s):  
Yu Su ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
High Speed ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
High Cutting Speed ◽  
Cryogenic Minimum Quantity Lubrication

Cryogenic minimum quantity lubrication (CMQL) is a kind of green cooling/lubrication technique, which consists of the application of a small amount of lubricant (6-100 ml/h), delivered in a refrigerated compressed gas stream to the cutting zone. This paper experimentally investigates the effect of CMQL on cutting temperature and tool wear in high-speed end milling of titanium alloys. Comparative experiments were conducted under different cooling/lubrication conditions, i.e. dry milling, refrigerated air cutting, and CMQL. The refrigerated gas equipment was manufactured based on composite refrigeration method to provide the refrigerated air. The experimental results show that application of CMQL resulted in drastic reduction in cutting temperature and tool wear especially when machining titanium alloys at a high cutting speed.

Numerical Simulation of High Speed Single-Grain Cutting Using a Coupled FE-SPH Approach

2013 ◽  
Vol 483 ◽  
pp. 3-8 ◽  
Author(s):  
Rui Dong Shen ◽  
Xiu Mei Wang ◽  
Chun Hui Yang
Keyword(s):  
Numerical Model ◽  
High Speed ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
High Cutting Speed ◽  
Particle Hydrodynamics ◽  
Single Grain ◽  
Cutting Processes

In this study, to simulate the grinding process for rolled homogeneous armor steel (RHA) 4043, a single-grain cutting process is modeled using a three-dimensional (3-D) numerical model, which is developed using a coupled finite element (FE) - smoothed-particle hydrodynamics (SPH) approach. The proposed numerical model is then employed to investigate the influences of grain negative rake angle (-22°, -31°, and-45°) as well as high and super-high cutting speed ranged from 100 m/s to 260 m/s in the cutting processes. The numerical results show the cutting forces are much lower and the maximum chip thickness is much larger when using a smaller grain negative rake angle.

scholarly journals Efecto de parámetros de mínima cantidad de lubricación en reducción de desgaste de herramienta

2019 ◽  
pp. 19-26
Author(s):  
Israel Martínez-Ramírez ◽  
Miguel Ernesto Gutiérrez-Rivera ◽  
Isaí Espinoza-Torres ◽  
Javier Rodríguez-Flores
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Vertical Angle ◽  
Low Level ◽  
High Cutting Speed ◽  
Designed Experiment ◽  
Aisi 1045 ◽  
High Level

The objective of this work is to determine the influence of Minimum Quantity Lubrication (MQL) parameters on flank wear during face milling. Furthermore, the values of each factor in which the MQL resulted to be effective were determined. A designed experiment with two level, three factor and two replicas was used to test tool wear on P45 grade inserts at relatively high cutting speed (~900 m/min) on steel AISI 1045. A commercial MQL system was used with vegetable base lubricant non soluble in water. Results show that amount of lubricant and vertical angle are key factors that affects the effectiveness of the process. A response surface equation was obtained in order to determine the zones in which the factors resulted in the lowest tool wear. A flank wear decrease of 7 times, respect to the maximum observed, was found by using low level of air flow, low level of vertical angle and high level of lubricant.

Experimental Analysis of Wear Mechanism and Tool Life in Dry Drilling of Al2024

2012 ◽  
Vol 566 ◽  
pp. 217-221 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Raja Ishak Raja Hamzah ◽  
Abdolkarim Niazi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dry Machining ◽  
Hole Quality ◽  
High Cutting Speed

Aluminum alloy is widely used in industry and various researches has been done on machiability of this material mainly due to its low weight and other superior properties. Dry machining is still interesting topic to reduce the cost of manufacturing and environmental contaminations. In present study dry machining of Al 2024 investigated on tool life, tool wear mechanisms, hole quality, thrust force and torque. Different types of high speed steel (HSS) tools utilized at constant feed rate of 0.04 mm/rev and cutting speeds within the range of 28 and 94 m/min. Experimental results revealed that HSCo drills, performed better than HSS drills in terms of tool life and hole quality. The main wear mechanisms which analyzed by scanning electron microscope found abrasive and adhesion wear on flank face, besides, BUE observed at chisel and cutting edges. However tool wear and BUE formation found more significant at high cutting speed. In terms of thrust force, two facet HSCo tools, recorded higher thrust force than four facet HSS drills.

Tool Life in High Speed Turning with Negative Rake Angle

2011 ◽  
Vol 264-265 ◽  
pp. 1009-1014 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz H.F. Al Hazza
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
High Speed Cutting ◽  
Life Estimation ◽  
High Speed Turning

The present work studies some aspects of turning process applied on mild steel using cermets tools at high speed cutting (1000mm/min) by using negative rake angle (0 to-12). The influence of increasing the cutting speed and negative rake angle on flank tool wear, cutting forces, feeding forces and tool temperature were analyzed. The research studies and concentrates on the tool life estimation and the effect of the negative rake angle and higher cutting speed on tool life. It was found that the maximum tool life is obtained in (-6) rake angle for the cutting parameters.

Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Sintered Steel

2015 ◽  
Vol 772 ◽  
pp. 72-76 ◽  
Author(s):  
Tadahiro Wada ◽  
Hiroyuki Hanyu
Keyword(s):  
Tool Wear ◽  
Cathode Material ◽  
Cutting Speed ◽  
Cemented Carbide ◽  
Coating Film ◽  
Sintered Steel ◽  
High Cutting Speed ◽  
Coated Tools ◽  
Coated Tool ◽  
Coated Cemented Carbide

In order to improve both the scratch strength and the micro-hardness of (Al,Cr)N coating film, the cathode material of an aluminum/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the aluminum/chromium target. In this study, hardened sintered steel was turned with (Al60,Cr25,W15)N, (Al60,Cr25,W15)(C,N), (Al64,Cr28,W8)(C,N), (Al,Cr)N and (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tool was experimentally investigated. The following results were obtained: (1) In cutting hardened sintered steel at the cutting speed of 0.42 m/s using the (Al60,Cr25,W15)N, the (Al60,Cr25,W15)(C,N), the (Al64,Cr28,W8)(C,N), the (Ti,Al)N and (Al,Cr)N coated tools, the wear progress of the (Al64,Cr28,W8)(C,N) coated tool became slowest among that of the five coated tools. (2) The wear progress of the (Al60,Cr25,W15)(C,N) coated tool was almost equivalent to that of the (Al64,Cr28,W8)(C,N) coated tool. However, at a high cutting speed of 1.67 m/s, the wear progress of the (Al60,Cr25,W16)(C,N) coated tool was faster than that of the (Al64,Cr28,W8)(C,N) coated tool.

Sign in / Sign up

Export Citation Format

Share Document