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.

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.

scholarly journals Finite Element Method of Nickel Chromium and Nickel Vanadium for Alternative CNC Machine Tool

2019 ◽  
Vol 9 (1) ◽  
pp. 4730-4733
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Tool Material ◽  
High Speed Steel ◽  
Life Time ◽  
Machining Process ◽  
Depth Of Cut ◽  
Cnc Machine ◽  
Element Analysis ◽  
Nickel Chromium

CNC tool is generally made of high speed steel (HSS) which has shorter life due to the increasing depth of cut. The steel shank wears within a short life time by the chips produced during machining process. And even the tool material cannot withstand a large amount of load. The damaged tool material is analysed and an alternate material is used to manufacture the tool. Alternate material used to manufacture the CNC tool which would have properties superior than HSS. The objective of this paper is to analyze the temperature increase & the thermal deformation of different materials like nickel-chromium and nickel-vanadium using Finite Element Analysis.

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.

Surface Quality of High Speed Milling of Silicon Carbide by Using Diamond Coated Tool

2013 ◽  
Vol 446-447 ◽  
pp. 275-278 ◽  
Author(s):  
Mohammad Iqbal ◽  
Mohamed Konneh ◽  
Ahmad Yasir Bin Md Said ◽  
Azri Fadhlan Bin Mohd Zaini
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
High Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Model Interaction ◽  
High Speed Milling ◽  
Coated Tool

The high speed milling of silicon carbide was discussed by using flat end-mill 2 mm in diameter diamond coated tool. Ultra-precision high speed spindle attachment was used to achieve cutting tool rotation speed as high as 50,000 rpm. Special fixture was designed to minimize the chatter on work-piece surface during the machining process. Three cutting parameters were selected as independent variables of the experiments. They were spindle speed, depth of cut and feed rate. The arithmetic mean value of roughness (Ra) was measured on the work-piece surface as the response of the experiment. Result of the experiment shows that the value of surface roughness can be achieved as low as 0.150 μm. Statistical analysis was provided to study the significant of the model, interaction among the cutting parameters and their effects to the surface roughness value.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

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. 

ANALYSIS OF CUTTING FORCES WHILE TURNING DIFFERENT MATERIAL

2020 ◽  
Vol 15 (4) ◽  
Author(s):  
Krishna Kumar M ◽  
Sangaravadivel P
Keyword(s):  
Cutting Force ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Tool Material ◽  
Radial Force ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Feed Force

The measurement of cutting forces in metal cutting is essential to estimate the power requirements, to design the cutting tool and to analyze machining process for different work and tool material combination. Although cutting forces can be measured by different methods, the measurement of cutting forces by a suitable dynamometer is widely used in industrial practice. Mechanical and strain gauge dynamometer are most widely used for measuring forces in metal cutting. The principle of all dynamometers is based on the measurement of deflections or strain produced from the dynamometer structure from the action of cutting force. In this project, a dynamometer is used to measure cutting force, feed force and radial force by using strain gauge accelerometer while turning different material in lathe. The dynamometer is a 500kg force 3- component system. As the tool comes in contact with the work piece the various forces developed are captured and transformed into numerical form system. In this project three forces of different materials such as aluminum, mild steel, brass, copper have been noted down. The forces on these materials with variation in speed and depth of cut are studied. Graphs are drawn on how these forces vary due to variation in speed.

Experimental thermal analysis and modelling of single point lathe cutting tools without cooling effect

2018 ◽  
Vol 7 (2) ◽  
pp. 276
Author(s):  
A. Agarwal ◽  
M.T Letsatsi ◽  
O.M. Seretse ◽  
R. Marumo
Keyword(s):  
Mild Steel ◽  
Feed Rate ◽  
High Speed ◽  
Single Point ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Work Piece ◽  
Comparison Of Experiments ◽  
Tungsten Carbide Tool

This study investigated the use of tungsten carbide tool and high speed steel (HSS) tool when machining aluminum and mild steel. The parameters such as feed and speed of rotation were varied in order to observe their effect on machining operation. The experiments were performed without a coolant. FLIR thermo Cam P60 and Infra-Red Camera were used to record the observations. The highest temperature were recorded when feed rate was 2 mm. A comparison of experiments shows that HSS tooling produced high temperatures when machining mild steel. At 625 rev/min HSS failed when cutting mild steel at 2 mm feed rate. It was generally observed that temperatures generated between a tool and work piece is a function of feed rate, speed of rotation and tool material. These observations can aid the selection of a tool before a machining operation.

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.

Analysis of Micro-Pin Manufacturing Using Inverse Slab Electrical Discharge Milling (ISEDM) Process

2011 ◽  
Vol 496 ◽  
pp. 247-252 ◽  
Author(s):  
Ruben Gil ◽  
J.A. Sánchez ◽  
N. Ortega ◽  
S. Plaza ◽  
B. Izquierdo ◽  
...  
Keyword(s):  
Aspect Ratio ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Process ◽  
Work Piece ◽  
Electrode Wear ◽  
Pulse Off Time

Abstract. This paper analyses the technological capabilities of a novel rotary (EDM) electrical discharge machining process for the manufacturing of high aspect ratio cylindrical micro-components. The process is called Inverse Electrical Discharge Grinding (ISEDM). An experimental analysis has been carried out on high speed steel (tool steel Vanadis 23), using a conventional EDM machine and graphite electrode. The effect of pulse off-time, work piece final diameter and machining length on material removal rate, electrode wear ratio, radial accuracy and surface roughness has been quantified. From the study, optimum strategies that involve the use of different EDM regimes for achieving the optimum requirements can be defined. Micro-pins of 0.3 mm diameter with aspect ratio as high as 100:1 have been successfully manufactured.

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