Experimental Investigations on Surface Roughness, Cutting Forces and Tool Wear in Turning of Super Duplex Stainless Steel With Coated Carbide Inserts

2017 ◽  
Author(s):  
Shirish Kadam ◽  
Rohit Khake ◽  
Sadaiah Mudigonda
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Duplex Stainless Steel ◽  
Cutting Speed ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Super Duplex Stainless Steel ◽  
Coated Carbide ◽  
Carbide Inserts

This paper addresses experimental investigations of turning Super Duplex Stainless Steel (DSS) with uncoated and Physical Vapor Deposition PVD coated carbide inserts under dry cutting condition. The parametric influence of cutting speed, feed and depth of cut on the surface finish and machinability aspects such as cutting force and tool wear are studied and conclusions are drawn. The turning parameters considered are cutting speed of 60–360 m/min, feed of 0.05–0.35 mm/rev and depth of cut of 0.5–2 mm. Tool wear was analysed by using an optical microscope and scanning electron microscope. The study includes identification of tool wear mechanism occurring on the flank face. The characterization of the coating was made by Calo test for measurement of coating thickness and nanoindentation for hardness. Comparison of performance of PVD coatings TiAlSiN (3.3μm), AlTiN (3 μm) and AlTiN (7 μm) have been made in terms of tool life. The coatings were produced on P-grade tungsten carbide inserts by using High Power Impulse Magnetron Sputtering (HiPIMS) technology. The findings of the study also provide the economic solution in case of dry turning of super DSS.

scholarly journals Machinability evaluation of coated carbide inserts in turning of super-duplex stainless steel

2020 ◽  
Vol 2 (11) ◽  
Author(s):  
Pranay Kumar Parsi ◽  
R. Sreeram Kotha ◽  
Thomas Routhu ◽  
Shashank Pandey ◽  
Maheshwar Dwivedy
Keyword(s):  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Super Duplex Stainless Steel ◽  
Coated Carbide ◽  
Carbide Inserts

Magnetic Damping in Turning of Stainless Steel AISI 304 for the Reduction of Machining Vibration and Tool Wear

2015 ◽  
Vol 1115 ◽  
pp. 100-103
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Siti Aminatuzzuhriyah B. Haji Subir ◽  
Fawaz Mohsen Abdullah
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Aisi 304 ◽  
Excited Vibration ◽  
Coated Carbide

Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.

The Use of TiAlN Coated Carbide Tool when Finish Machining Stainless Steel

2012 ◽  
Vol 224 ◽  
pp. 204-207
Author(s):  
Jozef Jurko ◽  
Anton Panda ◽  
Marcel Behún
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Stainless Steels ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Austenitic Stainless Steels ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Cutting Zone ◽  
Coated Carbide

This article presents conclusions of use TiAlN at drilling of a new austenitic stainless steels. This article presents the results of experiments that concerned the verification of the cutting tool wear. The results of cutting zone evaluation under cutting conditions (cutting speed vc=60 m/min, depth of cut ap= 3.0 mm and feed f= 0.04 mm per rev.) .

Cutting Forces and Tool Wear in Dry Milling of Ti6Al4V

2012 ◽  
Vol 565 ◽  
pp. 454-459 ◽  
Author(s):  
Yun Chen ◽  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Workpiece Material ◽  
Tool Wear Mechanism ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Cutting Speeds

Titanium alloys are difficult-to-cut materials. This paper presents an experimental study of the effects of different cutting conditions and tool wear on cutting forces in dry milling Ti6Al4V with coated carbide inserts. The experimental results show that the peak forces increase with the increase in the feed rate and depth of cut. With the cutting speed increment in the range from 50 m/min to 150 m/min the peak forces decrease, while at further higher cutting speeds investigated peak forces increase. The decrease of the peak forces is due to thermal softening of the workpiece material and the increase is because of the strain hardening rate of Ti6Al4V. The tool wear experiment reveals that the major tool wear mechanism is the flank wear. The variations of the peak forces are caused by both the tool wear propagation and the thermal effects.

Modeling of Tool Wear in Turning EN 31 Alloy Steel using Coated Carbide Inserts

2012 ◽  
Vol 2 (3) ◽  
pp. 34-51 ◽  
Author(s):  
Davinder Sethi ◽  
Vinod Kumar
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Alloy Steel ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
En 31 ◽  
Coated Carbide ◽  
Carbide Inserts

The experimental investigations of the tool wear in turning of EN 31 alloy steel at different cutting parameters are reported in this paper. Mathematical model has been developed for flank wear using response surface methodology. This mathematical model correlates independent cutting parameters viz. cutting speed, feed rate and depth of cut with dependent parameters of flank wear. This model is capable of estimating the tool wear at different cutting conditions. The central composite design has been used to plan the experiments. Coated carbide inserts have been used for turning EN 31 alloy steel. Results revealed that cutting speed is the most significant factor effecting flank wear, followed by depth of cut and feed rate. Flank wear increases with increase in all the three cutting parameters.

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.

Tool Wear Analysis in End Milling of Advanced Ceramics with TiAlN and TiN Coated Carbide Inserts

2012 ◽  
Vol 576 ◽  
pp. 76-79
Author(s):  
M. Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein ◽  
D. Sujan ◽  
Mohammad Yeakub Ali ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
High Hardness ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Carbide ◽  
Axial Depth

Advanced ceramic materials are difficult to machine by conventional methods due to the brittle nature and high hardness. The appropriate selection of cutting tool and cutting conditions may help to improve machinability by endmilling. Performance of TiAlN and TiN coated carbide tool insert in end milling of machinable glass ceramic has been investigated. Several dry cutting tests were performed to select the optimum cutting parameters for the endmilling in order to obtain better tool life. In this work, a study was carried out on the influence of cutting speed, feed rate and axial depth of cut on tool wear.The technique of design of experiments (DOE) was used for the planning and analysis of the experiments. Tool wear prediction model was developed using Response surface methodology.The results indicate that tool wear increased with increasing the cutting speed and axial depth of cut. Effect of feed rate is not much significant on selected range of cutting condition

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

scholarly journals Optimisation of the Machining of Stellite 6 PTA Hardfacing Using Surface Roughness

2010 ◽  
Vol 443 ◽  
pp. 227-231 ◽  
Author(s):  
Md Shahanur Hasan ◽  
Md Mazid Abdul ◽  
Richard E. Clegg
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Deposition Process ◽  
Depth Of Cut ◽  
High Corrosion Resistance ◽  
Turning Operations ◽  
Stellite 6 ◽  
Cutting Regimes ◽  
Coated Carbide ◽  
Carbide Inserts

Stellites are cobalt based super alloys. By virtue of their excellent physio-mechanical properties, stellites are highly regarded engineering materials. Stellites posses high corrosion resistance and wear resistance properties. This study investigates the Stellite deposition process and machinability of Stellite 6 deposited on steel subtrate. Stellite 6 was deposited onto a 4140 bar using a plasma transfer arc (PTA) system and machinability was assessed on the basis of surface roughness. A series of turning operations have been carried out on a conventional lathe using coated carbide inserts and surface roughness was evaluated by Stylus type Surtronic3+ instrument. The values of surface roughness were plotted against different cutting speed, feed rate and depth of cut to display the results in graphical forms. Optimal cutting regimes were established against the best values of surface roughness.

Investigation of Chip and Surface Roughness when Milling AISI304 Stainless Steel

2017 ◽  
Vol 889 ◽  
pp. 152-158
Author(s):  
K. Kadirgama ◽  
K. Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Feed Rate ◽  
Prediction Models ◽  
Cutting Speed ◽  
Experimental Result ◽  
Quadratic Model ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Axial Depth

Stainless steel was used for many engineering applications. The optimum parameters needs to be identify to save the cutting tool usage and increase productivity. The purpose of this study is to develop the surface roughness mathematical model for AISI 304 stainless steel when milling using TiN (CVD) carbide tool. The milling process was done under various cutting condition which is cutting speed (1500, 2000 and 2500 rpm), feed rate (0.02, 0.03 and 0.04 mm/tooth) and axial depth (0.1, 0.2 and 0.3 mm). The first order model and quadratic model have been developed using Response Surface Method (RSM) with confident level 95%. The prediction models were comparing with the actual experimental results. It is found that quadratic model much fit the experimental result compare to linear model. In general, the results obtained from the mathematical models were in good agreement with those obtained from the machining experiments. Besides that, it is shown that the influence of cutting speed and feed rate are much higher on surface roughness compare to depth of cut. The optimum cutting speed, feed rate and axial depth is 2500 rpm, 0.0212 mm/tooth and 0.3mm respectively. Besides that, continues chip is produced at cutting speed 2500 rpm meanwhile discontinues chip produced at cutting speed 1500 rpm.

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