The Effects of PVD Coated Tool Flank Wear and Process Parameters on Surface Integrity in Hard Milling AISI H13 Steel

2010 ◽  
Author(s):  
W. Li ◽  
Y. B. Guo
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Flank Wear ◽  
Cnc Machining ◽  
Inspection System ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Radial Depth ◽  
Aisi H13 ◽  
Accuracy And Repeatability

Interfacial friction between cutting tool and work material leads to tool wear during machining, which adversely affects surface integrity of machined components. In addition, more energy is expected to be consumed to accommodate higher loading during machining. Dimensional accuracy and repeatability of the workpiece is also hard to guarantee when machining with worn tools. In this paper, surface integrity of AISI H13 samples milled using the PVD coated inserts is studied. Three levels of tool flank wear (VB = 0, 0.1mm, 0.2mm) were used to cut H13 tool steel in the experiment. At each level of flank wear, the effects of cutting speed, feed, and radial depth-of-cut on surface integrity were investigated respectively. Under a diverse combination of milling parameters, the evolution of surface integrity with tool flank wear was analyzed. A novel on-line optical tool inspection system integrated with CNC machining center was used to inspect the evolution of flank wear with milling time in order to monitor tool wear conditions.

Tool Wear Influence on Surface Integrity and Fatigue Life of Hard Milled Surfaces

2011 ◽  
Author(s):  
W. Li ◽  
Y. B. Guo ◽  
M. E. Barkey
Keyword(s):  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Flank Wear ◽  
Cutting Speed ◽  
Critical Factor ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Radial Depth ◽  
Aisi H13 Tool Steel

In machining, the interfacial friction between cutting tool and work material leads to tool wear which is considered a critical factor for surface quality of machined components. Surface integrity and fatigue life of machined components will deteriorate when tool flank wear progresses in machining. Hard milling experiments on AISI H13 tool steel (50 ± 1 HRC) using PVD coated tools with different levels of flank wear were conducted in this study. Surface integrity of the machined components with flank wear VB = 0 mm, 0.1 mm and 0.2 mm was characterized. The effects of cutting speed, feed, and radial depth-of-cut on surface integrity were investigated respectively at the three levels of tool flank wear. In addition, four-point bending fatigue tests were performed on the milled samples at five levels of different flank wear (VB = 0, 0.05, 0.10, 0.15, 0.20 mm) to evaluate the trend of fatigue life evolution with the increased tool flank wear.

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.

Surface Integrity and Fatigue Strength of Hard Milled Surfaces

2011 ◽  
Author(s):  
W. Li ◽  
Y. B. Guo ◽  
M. E. Barkey ◽  
C. Guo ◽  
Z. Q. Liu
Keyword(s):  
Fatigue Life ◽  
Fatigue Strength ◽  
Surface Integrity ◽  
Endurance Limit ◽  
Flank Wear ◽  
Machining Accuracy ◽  
Tool Flank Wear ◽  
Radial Depth ◽  
Aisi H13 Tool Steel ◽  
Machined Surfaces

Tool flank wear during hard milling adversely affects surface integrity and, therefore, fatigue strength of machined components. Surface integrity and machining accuracy deteriorate when tool wear progresses. In this paper, surface integrity and its impact on endurance limit of AISI H13 tool steel (50 ± 1 HRC) by milling using PVD coated tools are studied. The evolutions of surface integrity including surface roughness, microhardness and microstructure were characterized at three levels of tool flank wear (VB = 0, 0.1mm, 0.2mm). At each level of tool flank wear, the effects of cutting speed, feed, and radial depth-of-cut on surface integrity were investigated respectively. Fatigue endurance limits of the machined surfaces at different reliability levels were calculated and correlated with the experimentally determined fatigue life. The good surface finish and significant strain-hardening on the machined surfaces enhance endurance limit, which enables machined components have a fatigue life over 106 cycles.

scholarly journals Effects of Tool Wear on Machined Surface Integrity During Milling of Inconel 718

2021 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Minchao Cui ◽  
Xuehong Shen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machined Surface Integrity

Abstract This paper investigates the effects of tool wear on the machined surface integrity characteristics, including the surface roughness, surface topography, residual stress, microhardness and microstructure, during ball-end milling of Inconel 718. Tool wear, tool lifetime, and cutting force are measured. In addition, a two-dimensional finite element-based model is developed to investigate the cutting temperature distribution in the chip–tool–workpiece contact area. Results show that the ball nose end mill achieves tool lifetime of approximately 350 min. The cutting forces increase sharply with a greater tool flank wear width, while the highest cutting temperature has a decreasing tend at a flank wear width of 0.3 mm. Higher tool flank wear width produces larger surface roughness and deteriorative surface topography. A high-amplitude (approximately −700 MPa) and deep layer (approximately 120 mm) of compressive residual stress are induced by a worn tool with 0.3 mm flank wear width. The surface microhardness induced by new tool is larger than that induced by worn tool. Plastic deformation and strain streamlines are observed within 10 mm depth beneath the surface. The results in this paper provide an optimal tool wear criterion which integrates the surface integrity requirements and the tool lifetime for ball-end finish milling of Inconel 718.

The Development of a Novel On-Line Optical Inspection System for Tool Conditions in Machining Processes

2010 ◽  
Author(s):  
W. Li ◽  
H. M. Singh ◽  
M. Salahshoor ◽  
Y. B. Guo
Keyword(s):  
Magnesium Alloys ◽  
Flank Wear ◽  
Optical Measurement ◽  
End Milling ◽  
Cnc Machining ◽  
Inspection System ◽  
Depth Of Cut ◽  
Machining Processes ◽  
On Line ◽  
Aisi H13 Tool Steel

Tool abrasion and material adhesion lead to tool flank wear and flank build-up respectively in machining magnesium alloys, which adversely affect surface integrity due to higher cutting forces and temperatures. In this paper, a novel on-line optical tool monitoring system integrated with CNC machining center is designed and applied to examining these two phenomena. Flank wear evolution on PVD coated inserts in end milling of AISI H13 tool steel and material adhesion on flank face of PCD inserts in face milling of lightweight magnesium alloys were on-line inspected to assess the function of the designed optical measurement system. Tool wear failure criterion for the PVD milling inserts is set to be VBmax = 250 μm and flank wear evolution with cutting time is presented. Tool/work adhesion between the PCD inserts and magnesium alloy were observed under different combinations of cutting parameters including speed, feed, and depth-of-cut. The advantages of the on-line optical tool inspection system are discussed.

Experimental Investigation on Tool Wear when End-Milling Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 410-415 ◽  
Author(s):  
Yuan Wei Wang ◽  
Jian Feng Li ◽  
Z.M. Li ◽  
Tong Chao Ding ◽  
Song Zhang
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Coated Carbide ◽  
Carbide Inserts

In this paper, some experiments were conducted to investigate tool wear when end-milling Inconel 718 with the TiAlN-TiN PVD coated carbide inserts. The worn tools were examined thoroughly under scanning electron microscope (SEM) with Energy Dispersive X-ray Spectroscopy and 3D digital microscope to expatiate tool wear morphologies and relevant mechanisms. The flank wear was uniformity in finishing milling process, and the average flank wear were selected as the criterion to study the effects of cutting parameters (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) on tool wear. Finally, the optimal combination of the cutting parameters for the desired tool life is obtained.

Effect of Tool Tilting Angle on Tool Wear and Surface Roughness in Micro Ball End Milling

2011 ◽  
Vol 325 ◽  
pp. 606-611 ◽  
Author(s):  
Kazuya Hamaguchi ◽  
Yuji Kagata ◽  
Hiroo Shizuka ◽  
Koichi Okuda
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Depth Of Cut ◽  
End Mill ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Tilting Angle ◽  
Radial Depth

This paper describes the effect of the tool tilting angle on the tool wear and the surface roughness in micro ball end milling. The cutting tests of hardened stainless steel were carried out by using of the micro ball end mill with radius of 100mm under the conditions of tilting angle from 0° to 45°. The spindle speed was fixed in a constant of 120,000 min-1. The feed per tooth, axial depth of cut and radial depth of cut were also fixed. The flank wear, the surface roughness and the cutting force were investigated. As a result, the maximum width of flank wear of the micro ball end mill tended to decrease with an increase in the tilting angle of spindle. The surface roughness became almost constant not depending on the tilting angle of the spindle.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

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.

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