The Effect of an Embedded Heat Pipe in a Cutting Tool on Temperature and Wear

2003 ◽  
Author(s):  
Richard Y. Chiou ◽  
Jim S. J. Chen ◽  
Lin Lu ◽  
Mark T. North
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Tool ◽  
Tool Material ◽  
Dimensional Accuracy ◽  
Chip Color ◽  
Radius Of Curvature ◽  
Skin Exposure ◽  
Fundamental Understanding ◽  
Cutting Tool Insert

This paper presents the fundamental understanding of the effect of an embedded heat pipe in a cutting tool on temperature and wear in machining. In particular, the technique can effectively minimize pollution and contamination of the environment caused by cutting fluids and the health problems of skin exposure and particulate inhalation in manufacturing. The temperature of a tool plays an important role in thermal distortion and the machined part’s dimensional accuracy, as well as in tool life in machining. A new embedded heat pipe technology has been developed to effectively remove the heat generated at the tool-chip interface in machining, thereby reduce tool wear and prolong tool life. Experiments were carried out to characterize the temperature distributions when performing turning experiments using a cutting tool installed with an embedded heat pipe. The ANSYS simulations show that the temperature near the cutting edge drops significantly with an embedded heat pipe during machining. Temperature measurements at several locations on the cutting tool insert agree with the simulation results both with and without the heat pipe. The effect of the heat pipe on reducing the cutting tool temperature was further supported by the observations of cutting tool material color, chip color, and chip radius of curvature.

Methods of Forecasting Wear Resistance of Cutting Tools Based on the Properties of their Materials

2014 ◽  
Vol 682 ◽  
pp. 491-494 ◽  
Author(s):  
Vladislav Bibik ◽  
Elena Petrova
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Chemical Properties ◽  
Tool Material ◽  
Composition Structure ◽  
Metal Cutting Tool ◽  
Physical And Chemical ◽  
Thermo Physical Properties

The author considers methods of forecasting metal-cutting tool life based on characteristics of cutting tool material. These characteristics depend on differences in numerical values of physical and chemical properties of tool material due to changes in its composition, structure, and production process variables. The described methods allow obtaining the information necessary for forecasting the tool life beyond the process of cutting, for example at the stage of cutting tool manufacturing. The author suggests using the method of registration of thermo-physical properties of the tool material as a promising forecasting technique.

Investigation of Heat Pipe Cooling in Drilling Applications: Part 2—Thermal, Structural Static, and Dynamic Analyses

2009 ◽  
Author(s):  
Lin Zhu ◽  
Tien-Chien Jen ◽  
Chen-Long Yin ◽  
Yi-Hsin Yen ◽  
Mei Zhu ◽  
...  
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Mechanical Effect ◽  
Machining Process ◽  
Drilling Process ◽  
Dynamic Analyses ◽  
Thermal Wear ◽  
3D Finite Element Method

Drilling is a highly complex machining process coupled with thermo-mechanical effect. Both the rapid plastic deformation of the workpiece and the friction along the drill-chip interface can contribute to localized heating and increasing temperature in the workpiece and tool. The cutting temperature at the tool-chip interface plays an important role in determining the tool thermal wear. This in turn affects the dimensional accuracy of the workpiece and the tool life of drill. A new embedded heat pipe technology has been proven to be able to effectively not only remove the heat generated at the tool-chip interface in drilling, but also minimize pollution and contamination of the environment caused by cutting fluids. Less tool wear can then be achieved, thus prolonging the tool life. 3D Finite Element method using COSMOS/works is employed to study coupled effects of thermal, structural static and dynamic analyses in a drilling process to check the feasibility and effectiveness of the heat pipe drill. Four different cases, solid drill without coolant, solid drill with coolant, heat pipe drill, and heat pipe drill with coolant, are explored, respectively. The results from this study can be used to define geometric parameters for optimal designs.

scholarly journals A Study of the Effect of Combining Multi-Sensor Signals and Cutting Chip Color on Tool Life Prediction

2021 ◽  
Author(s):  
Shao-Hsien Chen ◽  
Min-Sheng Gao
Keyword(s):  
Shear Zone ◽  
Tool Life ◽  
Life Prediction ◽  
Cutting Tool ◽  
Vibration Signal ◽  
Chip Color ◽  
General Regression Neural Network ◽  
Percentage Error ◽  
Voltage Signal ◽  
Sensor Signals

Often, engineers with machining experience often judge machining state and tool life according to chips’ features. Engineers' experience is digitized in this study. During the cutting process, the cutting tool coming in contact with the workpiece produces a shear zone, which causes plastic deformation and shear slip. The chips closest to the shear zone can directly show the state of the tool and workpiece when the material is SKD61. This study used chip color, vibration, and current signal integration for prediction of machining state and cutting tool life. When the cutting tool wears increased, the chip surface color changed in the following way: purpleè purple blueè blue ècyan, or even green and yellow. When the cutting tool was in the accelerating wear phase, the color change was particularly obvious. The Back-Propagation Levenberg–Marquardt (BP-LM) predictive methodology was used to compare the predictive ability of voltage, vibration signal, and chip color. The Mean Absolute Percentage Error (MAPE) for the voltage signal was 12.28%, for the vibration signal it was 11.38%, and for the chip color combined with multi-sensor characteristics it was 7.85%. The MAPE of the chip color was the smallest. Using the General Regression Neural Network (GRNN) methodology, the MAPE for the voltage signal was 10.74%, for the vibration signal 7.96%, and for the chip color combined with multi-sensor characteristics was 6.59%. The MAPE of the chip color was the smallest. Obviously, the chip color combined with multi-sensor signals provided better predictive results than the vibration signal or voltage signal alone. There is currently no research on the usefulness of monitoring chip color for tool life prediction.

Technical Resource of the Cutting Wedge is the Foundation of the Machining Regime Determination

2020 ◽  
Vol 10 (2) ◽  
pp. 1-17 ◽  
Author(s):  
Viktor P. Astakhov ◽  
Stanislav V. Shvets
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Tool Wear ◽  
Work Done ◽  
Cutting System ◽  
Small Tool

This article argues that cutting tool wear is not just a particular case of wear found in general machinery because the whole amount of energy required for cutting is transmitted through relatively small tool-chip and tool-workpiece interfaces causing extremely high contact temperatures and pressures. This article discusses a considerably different approach to the determination of the cutting speed based upon the energy passing through the cutting wedge. Moreover, it discusses that, for a given tool material/geometry, there is a limited amount of such energy that the cutting wedge can sustain before reaching the criterion of tool life. This limit is considered as the technical resource of the cutting tool. The article establishes and verifies the existence of the detect correlation between the works done in the cutting system and in tool wear. Based on this finding, the equations to calculate the cutting speed for a chosen tool life and/or the tool life for a chosen cutting speed are proposed. The concept of the technical resource of the cutting wedge is introduced as the total amount of work done before it fails.

Effect of residual elements on the machinability of leaded free machining steels

1980 ◽  
Vol 295 (1413) ◽  
pp. 87-88 ◽  
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Low Carbon ◽  
Wear Rates

The machinability of a material can be defined in terms of the wear rate of the cutting tool used to machine the material. The lower the tool wear rate or the greater the tool life the better the machinability. The wear processes of cutting tools are complicated, but recent work has shown that cutting tool wear rates during machining can be directly related to tool material wear rates when rubbing in a modified crossed cylinder wear experiment (Mills & Akhtar 1975). The wear of cutting tools can be simulated by simple experiments. Here I present results on the effect of total residual levels in leaded low carbon free machining steels on the tool life of M2 high speed steel. The results will be discussed in terms of a simple wear model.

Application Features of the Cutting Tool, Hardened by Laser Pulsed Radiation

2016 ◽  
Vol 870 ◽  
pp. 46-51
Author(s):  
S.I. Yaresko
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Process Analysis ◽  
Tool Material ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Irradiation Energy ◽  
High Feed ◽  
Cut Depth ◽  
Cutting Modes

The performed studies of the application features of the cutting tool, hardened by laser pulsed radiation are based on the comprehensive cutting process analysis. In this approach, the modeling results of the cutting process with hardened tool allowing to define the area of the effective use of laser treatment (LT). In particular, the increase in the tool life only for the certain values of the cut depth at the fixed irradiation energy was observed. The causes of the observed phenomena were determined based on durometric researches and studies of the microstructure in the contact zone. The measurements were performed for the cutters (steel R18) after turning structural steel 12Kh2N4A under various cutting modes. It was found that the processes of tool material softening, observed at turning with high feed values, limits the scope of cutting conditions by hardened tool. It is shown that LT leads to increased tool life, operating at the cutting conditions when the growth of tension thermodynamic in the cutting zone does not result in the development of softening processes. It is established that the area cutting modes are restricted to the values of cut depth not exceeding 1.5 mm (V=42.5 m/min, s=0.2 mm/rev) for the investigated pair of tool-workpiece (R18-12Kh2N4A). Tool life increases by more than 4 times compared to the durability of the non-irradiated tool provided the optimal combination of laser processing and hardened tool cutting modes is achieved.

scholarly journals Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

Coatings ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 855
Author(s):  
Sergey N. Grigoriev ◽  
Mars S. Migranov ◽  
Yury A. Melnik ◽  
Anna A. Okunkova ◽  
Sergey V. Fedorov ◽  
...  
Keyword(s):  
Surface Layer ◽  
Tool Life ◽  
High Speed ◽  
Composite Powder ◽  
Cutting Tool ◽  
Tool Material ◽  
High Speed Steel ◽  
Secondary Phase ◽  
The Coefficient Of Friction ◽  
Adaptive Materials

The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials. The tool material characteristics under the external loads’ influence and the surface layer adaptation to the heat–power exposure conditions were shown by the temperature field study using a semiartificial microthermocouple method (the level of fields is reduced by 20%–25% for 80% HSS + 20% TiCN), frictional interaction high-temperature tribometry (the coefficient of friction did not exceed 0.45 for 80% HSS + 20% TiCN at +20 and 600 °C), laboratory performance tests, and spectrometry of the surface layer secondary structures. Spectral analysis shows the highest spectrum intensity of TiC2 after 5 min of running in. After 20 min of milling (V = 82 m/min, f = 0.15 mm/tooth), dicarbide decomposes and transits to thermally stable secondary phase films of good lubricity such as TiO (maximum) and TiN (partially). There was an increase in tool life of up to 2 times (>35 min for 80% HSS + 20% TiCN), and a decrease in the roughness of up to 2.9 times (Ra less than 4.5 µm after 25 min of milling).

Study of Properties of Nanostructured Multilayer Composite Coatings of Ti-TiN-(TiCrAl)N and Zr-ZrN-(ZrNbCrAl)N

2016 ◽  
Vol 40 ◽  
pp. 90-98 ◽  
Author(s):  
Alexey Anatolevich Vereschaka ◽  
Anatoliy Stepanovich Vereschaka ◽  
Jury I. Bublikov ◽  
Anatoliy Y. Aksenenko ◽  
Nikolay N. Sitnikov
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Composite Coatings ◽  
Tool Material ◽  
Multilayer Composite ◽  
Functional Coatings ◽  
Surface Layers ◽  
X Ray ◽  
Resistant Layer ◽  
Nanostructured Multilayer Composite Coatings

The structures of surface layers of the tool material, adapted to the conditions of the thermomechanical loading during the cutting process, can be formed with the use of different processing methods, the most effective of which is to deposit functional coatings on working surfaces of the cutting tool. During the studies, two nanostructured multilayer composite coatings (NMCCs) were considered: Ti-TiN-(TiCrAl)N and Zr-ZrN-(ZrNbCrAl)N. Metallographic studies were conducted, and the phase compositions of the coatings were determined by X-ray crystal analysis. The efficiency of tools made of carbide T14K8 with developed coatings was determined by comparative evaluation of tool life of a tool without coating, a tool with standard coating (TiN), and a tool with elaborated coatings (Ti-TiN-(TiCrAl)N and Zr-ZrN-(ZrNbCrAl)N) in turning structural steel 45. These tests allow noting the increase in tool life of a tool with elaborated NMCCs by up to 4 times as compared with tool life of an uncoated tool and by up to 2 times as compared with tool life of standard coating TiN. Meanwhile, NMCC of Ti-TiN-(TiCrAl) showed lifetime about 10% longer than NMCC of Zr-ZrN-(ZrNbCrAl)N). The longer lifetime of NMCC of Ti-TiN-(TiCrAl) conforms to its better adhesion characteristics and thinner nanosublayers of its wear-resistant layer.

Lifetime predictions for a ceramic cutting tool material at high temperatures

1987 ◽  
Vol 22 (6) ◽  
pp. 2051-2057 ◽  
Author(s):  
B. Gurumoorthy ◽  
K. Kromp ◽  
F. B. Prinz ◽  
A. C. Bornhauser
Keyword(s):  
High Temperatures ◽  
Cutting Tool ◽  
Tool Material ◽  
Ceramic Cutting Tool
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