Experimental Investigations to Evaluate the Performance of Alternate Striped Coated Carbide Inserts in Turning of AISI 1040 Steel

2015 ◽  
Author(s):  
L. V. R. S. V. Prasad Chilamkurti ◽  
Naga Lakshmi Pavani Puvvada ◽  
Ramji Koona ◽  
Venkata Ramana Swarna
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Single Layer ◽  
Cutting Edge ◽  
Experimental Investigations ◽  
Clear Understanding ◽  
Rake Face ◽  
Machining Conditions ◽  
Coated Tools ◽  
Coated Carbide

During machining in order to improve the performance of the tool, it is necessary to have a clear understanding of chip flow and chip-tool interactions on the rake face. The predominating factors which influence the performance of cutting tool are proper combinations of process variables, tool and workpiece. Focusing more on environmental and economic considerations, dry machining is preferred in the present work to study and evaluate the performance of the multi-striped alternate coated Tungsten Carbide (WC) inserts. Dry turning tests on AISI 1040 steel at various machining conditions have been carried out using uncoated and striped coated cutting tools to deliberate the wear patterns close to the cutting edge. An effective tool coating helps the tool manufacturers to increase the tool life during high speed machining conditions. In the earlier research, in evaluating the performance of single and multi-layer carbide tools, tool wear has been considerably reduced in multi-layer coated tools compared with single layer coated tools. In the current work, to further reduce the tool wear an attempt has been made to assess the tool wear with striped coated carbide tools having alternate bands of hard and soft coatings located close to the cutting edge. The findings are significant in the current study which shows that no crater wear has been observed. Further authors also tried for the optimum rake face utilization by having the proposed band of coatings close to the cutting edge.

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Machinability of Pearlitic Cast Iron With Cubic Boron Nitride (CBN) Cutting Tools

2002 ◽  
Vol 124 (4) ◽  
pp. 820-832 ◽  
Author(s):  
Jiancheng Liu ◽  
Kazuo Yamazaki ◽  
Hiroyuki Ueda ◽  
Norihiko Narutaki ◽  
Yasuo Yamane
Keyword(s):  
Cast Iron ◽  
Boron Nitride ◽  
Tool Wear ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Conditions ◽  
Machining Center

In order to increase the accurate finishing productivity of pearlitic cast iron, face milling by CBN (Cubic Boron Nitride) cutting tools was studied. The main focus of the study is the machinability investigation of pearlitic cast iron with CBN cutting tools by studying the relationships among machining conditions such as feed rate, cutting speed as well as CBN cutting tool type, tool wear, workpiece surface quality, cutting forces, and cutting temperature. In addition, an emphasis is put on the effect of Al additive in pearlitic cast iron on its machinability and tool wear characteristics. High-speed milling experiments with CBN cutting tools were conducted on a vertical machining center under different machining conditions. The results obtained provide a useful understanding of milling performance by CBN cutting tools.

Tool Wear Mechanisms in High Speed Machining Ductile Cast Iron

2010 ◽  
Vol 29-32 ◽  
pp. 1527-1531
Author(s):  
Fa Zhan Yang ◽  
Jian Qiang Zhou ◽  
Guang Yao Meng ◽  
Jun Zhao ◽  
Chang He Li
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Wear Behavior ◽  
Orthogonal Cutting ◽  
Ductile Cast Iron ◽  
Cemented Carbide ◽  
Rake Face ◽  
High Speed Cutting

Wear behavior of WC based nanocomposite cutting tool when high speed cutting ductile cast iron was investigated. Orthogonal cutting tests were carried out on a CA6140 lathe using three speeds, namely, 100, 215 and 287m min-1. The WC based nanocomposite tool is found to be superior to cemented carbide tools (YG8). The tool life is prolonged 60% as compared to cemented carbide, as the width of the wear land (VB), which was monitored at selected time intervals. Meanwhile, the topography of worn surfaces was scanned by a profilemeter. Wear characterization of the rake face and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM). Results showed that distinctive traces of single abrasive tool wear event were found on the rake face of the tool, additionally, the adhesion wear is the main wear mechanism in the flank face of the tool. However, the extent of improvement in tool life depends strongly on the cutting conditions, with the greatest benefits being seen at higher cutting speeds and feed rates.

Experimental Study on the Thread Turning Performance of Two TiAlN Coated Thread Inserts with Different Features

2013 ◽  
Vol 797 ◽  
pp. 149-154
Author(s):  
Kang Li ◽  
Peng Nan Li ◽  
Ming Chen
Keyword(s):  
Experimental Study ◽  
Tool Wear ◽  
Coating Thickness ◽  
Matrix Material ◽  
Chip Morphology ◽  
Rake Face ◽  
Type Alloy ◽  
Alloy Matrix ◽  
Coating Technology ◽  
Coated Tools

With the development of the coating technology, coated tools have been widely used in processing industries. Thread turning is one of its applications. The performance of coated thread inserts varies with the change of coating material, coating thickness, matrix material and tool structure. Two tungsten-cobalt type alloy matrix, TiAlN coated thread inserts with different coating thickness, rake face type had been employed to conduct the thread turning experiments. By analyzing the cutting forces, chip formation and tool wear, it was found that insert with coating thickness of 4.35 μm would result in less tool wear under MQL condition, smaller cutting force, better chip morphology under dry condition compared with insert with coating thickness of 2.38 μm.

A Study on Driven-Type Rotary Cutting for Finish Turning of Carburized Hardened Steel

2012 ◽  
Vol 523-524 ◽  
pp. 250-255 ◽  
Author(s):  
Hideharu Kato ◽  
Tatsuya Shikimura ◽  
Yoshitaka Morimoto ◽  
Kazuhiro Shintani ◽  
Toshio Inoue ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
High Efficiency ◽  
Single Point ◽  
Hardened Steel ◽  
Cutting Edge ◽  
Finish Turning ◽  
Cutting Length ◽  
Rotary Cutting

Recently, cutting has replaced grinding in the finish processing of hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high feed rate conditions instead of the present cutting conditions. Therefore, the examination of a new cutting technique that can realize high-efficiency cutting is desired. In this study, the effects and efficiency of driven rotary cutting are investigated in the finish turning of carburized hardened steel. Based on the results, flaking occurs at the cutting edge at a short cutting length of 0.2 km using single-point turning. On the other hand, even if the cutting length amounts to 1.5 km, the tool wear width without flaking is small in the case of a driven rotary tool. Additionally, the tool wear is uniformly distributed along the circumference of the cutting edge. Furthermore, based on an examination of high-efficiency processing by increasing the feed rate, it is clarified that a feed rate of 0.3 mm/rev is the optimum condition from the viewpoint of wear resistance and surface roughness. Additionally, even if the cutting length amounts to 5.0 km for this condition, the flank wear width is as small as 0.04 mm, and the tool wear progresses gradually.

scholarly journals Research on Slicing Chip Forming and Wear Analysis of Arc-tooth Slice Tool With Equal-rake Angle

2021 ◽  
Author(s):  
Xiaoqiang Wu ◽  
YONGQUAN JIN
Keyword(s):  
Tool Wear ◽  
Race Model ◽  
Rake Angle ◽  
Cutting Edge ◽  
Tooth Surface ◽  
Surface Model ◽  
Rake Face ◽  
Widespread Application ◽  
Geometry Model ◽  
Slicing Technology

Abstract As a new technology of gear processing, the gear slicing technology has distinct characteristics and broad application prospects. However, the lack in wear and life of the slice tool hinders the further widespread application of the gear slicing technology. Considering the chip forming mechanism is an important basis affecting the wear and service life of the cutter, this paper takes the arc-tooth slice tool with equal-rake angle (ATST-ERA) as the carrier and studies the chip forming and tool wear. Aiming at the particularity of the slicing process, the cutting process is unified and abstracted, and the cutting edge model, the cutting edge race model and the workpiece tooth surface model of the ATST-ERA are established, and then the undeformed chip geometry model is obtained. The correctness of the parametric model of the undeformed chip was verified by comparative analysis. Based on this model, the load of the cutting edge is calculated using the Kienzle empirical formula of the cutting force. By analyzing the relationship with the wear of the rake face, the positive correlation between the cutting edge load and the rake face wear of the ATST-ERA is found. The chip forming modeling method proposed in this paper provides a theoretical basis for the control of the slicing chip forming and the improvement of tool wear.

scholarly journals Effect of Volcano-like Textured Coated Tools on Machining of Ti6Al4V: An Experimental and Simulative Investigation

2021 ◽  
Author(s):  
Yun Zhou ◽  
Yonghong Fu ◽  
Jie Yang
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Material Model ◽  
Ti6al4v Alloy ◽  
Cutting Conditions ◽  
Vacuum Arc ◽  
Rake Face ◽  
Coated Tools ◽  
Coated Tool

Abstract In this work, the main aim is to reduce the adhesion and wear that happened during machining of the Ti6Al4V alloy by employing volcano-like texture on the rake face of coated tool. A combination of experimental and simulative investigation was adopted. DEFORM-3D software with updated Lagrangian formulation was used for numerical simulation, and the thermo-mechanical analysis was performed using Johnson-Cook material model to predict the cutting temperature, cutting forces, chip morphology and tool wear. In cutting experiments, volcano-like textures with different area densities (10%, 20%, 30%) were fabricated by fiber laser on the rake face of cemented carbide tools close to the main cutting edge. Then, these textured tools were deposited with CrAlN coating through cathodic vacuum arc ion plating technique. Experiments in cutting Ti6Al4V alloy were carried out with the textured coated tools and non-textured coated tool under dry and wet cutting conditions. Then, the chip morphology, chip size and tool wear were investigated. The results showed that textured coated tools were superior to conventional tool. Especially in wet cutting, compared with those of non-textured coated tool, the adhesion area and the chip curling radius of the coated tool with texture area density of 20% (VCT2) were reduced by 31.2% and 49.7%, respectively. Therefore, VCT2 tool showed a better cutting performance. Finally, the mechanisms of textured coated tools under dry and wet cutting conditions were proposed.

scholarly journals Study on High-Efficiency Finish Turning of Carburized Hardened Steel with Driven Rotary Cutting

2013 ◽  
Vol 7 (3) ◽  
pp. 321-328 ◽  
Author(s):  
Hideharu Kato ◽  
◽  
Tatsuya Shikimura ◽  
Yoshitaka Morimoto ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
High Efficiency ◽  
Single Point ◽  
Hardened Steel ◽  
Cutting Edge ◽  
Finish Turning ◽  
Cutting Length ◽  
Rotary Cutting

Recently, cutting has replaced grinding in the finish processing of hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high-feed rate conditions instead of the present cutting conditions. Therefore, the examination of a new cutting technique that can realize high-efficiency cutting is desired. In this study, the effects and efficiency of driven rotary cutting are investigated in the finish turning of carburized hardened steel. Based on the results, flaking occurs when single-point turning is used at the cutting edge at a short cutting length of 0.2 km. On the other hand, even if the cutting length amounts to 5.0 km, the tool wear width without flaking is small in the case of driven rotary cutting. Additionally, the tool wear is uniformly distributed along the circumference of the cutting edge. Furthermore, based on an examination of high-efficiency processing by increasing the feed rate, it is found that a feed rate of 0.3 mm/rev is the optimum condition from the viewpoint of wear resistance and surface roughness. Additionally, even if the cutting length amounts to 5.0 km for this condition, the flank wear is as narrow as 0.04 mm, and the tool wear progresses gradually.

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