Microscopic Tool Wear in Machining Aluminum 6061 T6 (Cold Compressed Air, Nitrogen and Dry Environments

2013 ◽  
Author(s):  
Vishnu Vardhan Chandrasekaran ◽  
Lewis N. Payton
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Chip Thickness ◽  
High Speed Steel ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Work Piece ◽  
Labview Software ◽  
Designed Experiment ◽  
Force Data

The current study is a statistically designed experiment to evaluate different cutting environments that can be used in machining aluminum 6061 T6. High speed steel inserts were used along with different levels of uncut chip thickness in a classic orthogonal tube turning experiment. The cutting fluids used in this study are nitrogen and cold compressed “shop” air that are compared to the results obtained from dry machining. The force data (cutting force and the thrust force) were collected using a Kistler force dynamometer and processed using Labview software. The tools are subjected to 1 minute of cutting at two different feed rates of 0.002″/rev. and 0.004″/rev at a constant depth of cut of 0.125″ and at a constant speed. The tool inserts after 1 minute of cutting are studied for tool wear using a Keyance microscope. The surface finish of the work piece surface (average surface roughness) after one minute of cutting is examined under a Dektak 150 contact type surface profilometer. Alternative metal working fluid options are discussed.

Evaluation of Forces, Tool Wear and Surface Finish During Orthogonal Machining AISI 1020 Steel in Three Cutting Environments

2013 ◽  
Author(s):  
Vishnu Vardhan Chandrasekaran ◽  
Lewis N. Payton
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
High Speed ◽  
Tool Material ◽  
High Speed Steel ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Average Roughness ◽  
Labview Software

A large statistically designed orthogonal tube turning experiment measuring the forces, tool wear and surface finish involved in machining of AISI 1020 steel under four different cutting environments. The environments studied were nitrogen and cold compressed air against dry machining. Each data run consisted of one minute cutting time at two different feeds of 0.002″/rev. and 0.004″/rev. at a constant depth of cut of 0.125″ width of cut using High speed steel tool material inserts. Post-mortem analysis was carried out under a Keyance microscope to evaluate the wear on the rake face. The cutting force and the thrust force are collected during the machining process with a dynamometer and the data is further processed using Labview software. The surface finish on the work piece after the cutting process is also evaluated based on the average roughness measurement taken from a contact type profilometer. The advantages of using such gaseous cutting fluids are discussed.

A Study on the Parameters in Hard Turning of High Speed Steel

2018 ◽  
Vol 5 (2) ◽  
pp. 1-12
Author(s):  
Krishnaraj Vijayan ◽  
N. Gouthaman ◽  
Tamilselvan Rathinam
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Hard Turning ◽  
White Layer ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Contributing Factors

The objectives of hard turning of high speed steel (HSS-M2 Grade) are to investigate the effect of cutting parameters on cutting force, tool wear and surface integrity. This article presents the experimental results of heat treated high speed steel machined in a CNC lathe using cubic boron nitride (CBN) tools. Turing experiments were carried out using central composite design (CCD) method. From the experiments the influence of cutting parameters and their interactions on cutting forces, temperature and surface roughness (Ra) were analyzed. Following this, multi response optimization was done to find the best combination of parameters for minimum force, minimum temperature and minimum surface roughness. The experimental results showed that the most contributing factors were feed followed by depth of cut and spindle speed. A white layer formed during hard turning was also analyzed by scanning electron microscope (SEM) and the results showed that it was greatly influenced by the speed and depth of cut. Tool wear was experiments were conducted at the optimum cutting conditions and it was noted that the tool satisfactorily performed up to 10 minutes at dry condition.

scholarly journals Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

2016 ◽  
Vol 1 (2) ◽  
pp. 65-70
Author(s):  
Norsalawani Binti Mohamad ◽  
Rubina Bahar
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Limiting Factors ◽  
Work Piece ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Overall Performance

Miniature drilling is widely used in industries including electronics and reconstructive surgeries to create small sized holes. Chip removal and effective supply of coolant are the two limiting factors that make the process more complex compared to other meso scale machining processes and also contribute to the tool wear. The tool wear in the process is mainly caused by the interaction, motion and chip production between the tool and work piece. Uniform supply of coolant must be ensured to reach the drilled cavity to keep the tool wear to a minimal level. This study includes experimental investigation of the tool condition after applying Minimum Quantity Lubrication (MQL) system as a greener approach as the name indicates. The tool condition with MQL has also been compared with dry and flood cooling. Two different types of drill bit materials (High Speed Steel and Carbide) have been tested under same experimental condition to drill through Aluminum Alloy 6061 and it has been found that overall performance in terms of tool condition after applying MQL was better compared to the other two methods. The overall wear propagation area was measured for both the conditions. It was seen, the wear propagation covered minimal area with MQL while for flood and dry condition wear was spread over a bigger area on flank. 

Multivariate Analysis of Orthogonal Tube Cutting Forces With 3-D Tool Wear Analysis of AISI 1020 Alloy Steel Using Cold Compressed Air Versus Liquid Nitrogen as Metal Working Fluids

2015 ◽  
Author(s):  
Vishnu Vardhan Chandrasekaran ◽  
Lewis N. Payton ◽  
Wesley S. Hunko
Keyword(s):  
Multivariate Analysis ◽  
Liquid Nitrogen ◽  
High Speed ◽  
High Speed Steel ◽  
Compressed Air ◽  
Working Fluid ◽  
Metal Working ◽  
Factor Level ◽  
Working Fluids ◽  
Force Data

The growing cost associated with insurance, handling and disposing of conventional metal working fluids (oil and water based) continues to drive a need for alternative metal working fluids. An orthogonal tube turning machining experiment on AISI 1020 alloy steel was conducted to study the performance of High Speed Steel (HSS) tool inserts and carbide tool inserts utilizing cold compressed air and liquid nitrogen environments as the metal working fluid of choice The use of both high speed steel and carbide inserts allowed for direct comparison of geometrically identical inserts in customized tool holders that were used to present the tools with the geometrically identical tool rake angle alpha. Tool holder stiffness was therefore common to all tool rake angles compared. AISI 1020 steel was used because of its commercially dominant availability and usage. Cold cryogenic cooling was selected because of its growing usage in high performance machining applications. The use of cold compressed air has been much less studied in the machining of metals than in the machining of plastics and composites where it is quite commonly used. The comparisons between these two methods represent the first published values comparing the current extremes of gaseous metal working fluid applications in a commercial steel. This statistically designed experiment produced a large amount of comparative data that focused on the wear of the tools in two different cutting environments allowing for multivariate analysis of variance and regressive curve fitting. The orthogonal tube turning was set up on a conventional two axis HAAS TL-2 CNC tool room lathe. Forces were collected utilizing a standard Kistler force dynamometer to record the force data in X, Y and Z axes. Two levels of uncut chip thickness, 0.002 and 0.004” per revolution were maintained with a constant feed and depth of cut of 0.125” at different tool rake angles of 0°, 7° and 15°, with no chip breaker installed in the tool. Tool rake angles and depth of cuts were selected to ensure maximum statistical power/decisiveness of the experiment. The experiment was carried out for duration of 1 minute while the force data was collected for the entire duration of cut. New tool insert was used for each factor level combination. The traditional force analysis results are provided for an orthogonal tube turning experiment. In addition, all tools were analyzed for 3-dimensional rake face wear using an innovative Keyence white light microscope. Surprisingly, the inexpensive, simple cold compressed air produced less wear than the more expensive liquid nitrogen for all cutting factor level combinations.

Orthogonal Turning of Aluminum 6061 in Liquid Nitrogen Cutting Environment

2014 ◽  
Author(s):  
Vishnu Vardhan Chandrasekaran ◽  
Lewis N. Payton ◽  
Wesley Scott Hunko
Keyword(s):  
Tool Wear ◽  
Liquid Nitrogen ◽  
Hard Turning ◽  
Three Dimensional ◽  
Optical Microscope ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Orthogonal Turning ◽  
Force Data

Liquid nitrogen is studied as an alternative metal working fluid during the machining of Aluminum 6061-T6 alloy using two different tool materials (HSS and an uncoated carbide). The design of the experiment utilized two feeds (0.002”/rev and 0.004”/rev) with a constant depth of cut (0.125 inch) and 3 different tool rake angles of 0°, 7° and 15°. Force data was collected using Kistler dynometer. Three-dimensional (3D) measurements of the tool wear were analyzed using a 3D Keyence optical microscope in conjunction with a Dektak surface profilometer. When contrasted with dry cutting (hard turning), it was found that the liquid nitrogen increased the tool wear with HSS tools but decreased tool wear using uncoated carbide tools. Effect on cutting forces in all cases was statistically insignificant.

A Fracture Mechanics Approach to the Prediction of Tool Wear in Dry High Speed Machining of Aluminum Cast Alloys: Part 2 — Model Calibration and Verification

Tribology ◽  
2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Fracture Mechanics ◽  
Tool Wear ◽  
Model Calibration ◽  
High Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Wear Model ◽  
Wide Range ◽  
Cast Alloys

Experimental study has been carried out to establish the effect of cutting conditions (speed, feed, and depth of cut) on the cutting forces and time variation of carbide tool wear data in high-speed machining (face milling) of Al-Si cast alloys that are commonly used in the automotive industry. The experimental setup and force measurement system are described. The test results are used to calibrate and validate the fracture mechanics-based tool wear model developed in Part 1 of this work. The model calibration is conducted for two combinations of cutting speed and a feed rate, which represent a lower and upper limit of the range of cutting conditions. The calibrated model is then validated for a wide range of cutting conditions. This validation is performed by comparing the experimental tool wear data with the tool wear predicted by calibrated cutting tool wear model. The prediction errors were found to be less then 7%, demonstrating the accuracy of the object oriented finite element (OOFE) modeling of the crack propagation process in the cobalt binder. It also demonstrates its capability in capturing the physics of the wear process. This is attributed to the fact that the OOF model incorporates the real microstructure of the tool material.

Plasma Surface Alloying W-Mo Low-Alloy HSS

2005 ◽  
Vol 475-479 ◽  
pp. 3955-3958
Author(s):  
Jin Yong Xu ◽  
Yan Ping Liu ◽  
Yuan Gao ◽  
Zhong Xu
Keyword(s):  
High Speed ◽  
Surface Hardness ◽  
High Speed Steel ◽  
Alloying Elements ◽  
Work Piece ◽  
Test Results ◽  
Surface Alloying ◽  
Plasma Surface ◽  
The Common ◽  
Plasma Surface Alloying

The plasma surface alloying low-alloy high speed steel (HSS) is carried out in vacuum chamber where a source electrode (W-Mo) and a work piece are properly placed. By using the sputter of glow-discharge, under the common function of electric field and temperature field, ?????? the desired alloying elements (W- Mo) are sputtered from the source cathode, traveling toward the substrate. Subsequently the alloying elements deposit onto the surface of the substrate, forming alloy diffusion layer which the depth may vary from several micron to several hundreds micron. In the end a surface low-alloy HSS steel would be produced after ultra-saturation ion carbonization. The composition of the alloyed layer is equal or similar with it of low-alloy HSS. The carbonized layer, without coarse eutectic ledeburite structure, possesses high density of finely and dispersed alloy carbides with tungsten equivalent 10% above and a significant improvement in surface hardness and wear resistance. The principle of plasma surface alloying and its test results and commercial products application are introduced in this paper.

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.

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

2021 ◽  
Vol 18 (4) ◽  
pp. 9188-9207
Author(s):  
Mahendran Samykano ◽  
J. Kananathan ◽  
K. Kadirgama ◽  
A. K. Amirruddin ◽  
D. Ramasamy ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
Alumina Nanoparticles ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Nanoparticle Concentration

The present research attempts to develop a hybrid coolant by mixing alumina nanoparticles with cellulose nanocrystal (CNC) into ethylene glycol-water (60:40) and investigate the viability of formulated hybrid nanocoolant (CNC-Al2O3-EG-Water) towards enhancing the machining behavior. The two-step method has been adapted to develop the hybrid nanocoolant at various volume concentrations (0.1, 0.5, and 0.9%). Results indicated a significant enhancement in thermal properties and tribological behaviour of the developed hybrid coolant. The thermal conductivity improved by 20-25% compared to the metal working fluid (MWF) with thermal conductivity of 0.55 W/m℃. Besides, a reduction in wear and friction coefficient was observed with the escalation in the nanoparticle concentration. The machining performance of the developed hybrid coolant was evaluated using Minimum Quantity Lubrication (MQL) in the turning of mild steel. A regression model was developed to assess the deviations in the tool flank wear and surface roughness in terms of feed, cutting speed, depth of the cut, and nanoparticle concentration using Response Surface Methodology (RSM). The mathematical modeling shows that cutting speed has the most significant impact on surface roughness and tool wear, followed by feed rate. The depth of cut does not affect surface roughness or tool wear. Surface roughness achieved 24% reduction, 39% enhancement in tool length of cut, and 33.33% improvement in tool life span. From this, the surface roughness was primarily affected by spindle cutting speed, feed rate, and then cutting depth while utilising either conventional water or composite nanofluid as a coolant. The developed hybrid coolant manifestly improved the machining behaviour.

scholarly journals Optimization of Boring Process Parameters in Manufacturing of Polyacetal Bushing using High Speed Steel

2019 ◽  
Vol 130 ◽  
pp. 01031 ◽  
Author(s):  
The Jaya Suteja ◽  
Yon Haryono ◽  
Andri Harianto ◽  
Esti Rinawiyanti
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Optimum Result ◽  
Edge Angle

Polyacetal is commonly used as bushing material because of its low coefficient of friction and self lubricant characteristics. The polyacetal is machined by using boring process to produce bushing in certain surface roughness. The objectives of this research are to optimize three independent parameters (depth of cut, feed rate and principal cutting edge angle) of boring process of polyacetal using high speed steel tool to achieve the highest material removal rate and the required surface roughness. Response Surface Methodology is used to investigate the influence of the parameters and optimize the boring process. The research shows that the influence of the boring process parameters on polyacetal is similar compared to on metal. The result reveals that the optimum result is achieved by applying the value of depth of cut, feed rate, and principal cutting edge angle is 2.9 × 10–3 m, 0.229 mm rev–1, and 99.1° respectively. By applying these values, the maximum material rate removal achieved in this research is 1263.4 mm3 s–1 and the surface roughness achieved is 1.57 × 10–6 m.

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