Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

High-Speed Machining of Ti-6Al-4V With a Micro Textured Cutting Tool Focusing on Coolant Behaviors

2020 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Production Efficiency ◽  
Cutting Tool ◽  
Failure Process ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
High Speed Machining ◽  
Textured Surfaces

Abstract In the cutting of Ti-6Al-4V alloy, the cutting speed is limited as a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. However, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face significantly suppresses both crater wear and flank wear. In addition, optimum texture structures and the mechanism of the texture effects in high-speed machining of Ti-6Al-4V alloy were discussed.

scholarly journals MQL Machining with nano fluid: a review

2021 ◽  
Vol 8 ◽  
pp. 13
Author(s):  
Pralhad B. Patole ◽  
Vivek V. Kulkarni ◽  
Sudhir G. Bhatwadekar
Keyword(s):  
Surface Finish ◽  
High Speed ◽  
Metal Cutting ◽  
Experimental Studies ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Work Piece ◽  
Nano Fluid

In any metal cutting machining operation, the cutting fluid plays important role by cooling the cutting tool and the surface of the work piece, also chips are removed from heat affected zone. However, misuse of the cutting fluid and wrong methods of its disposal can affect human health and the environment badly. This paper presents a review of the important research papers published regarding the MQL-based application of mineral oils, vegetable oils and nano fluid-based cutting fluids for different machining processes, such as, drilling, turning, milling and grinding, etc. Most of the experimental studies have shown that application of MQL produces surface better than the flood and dry machining. In turning operation, parameters such as cutting speed, depth of cut, feed rate and tool nose radius have great impact on the surface finish. During high speed turning of steel inherently generates high cutting zone temperature. Such high temperature causes dimensional deviation and failure of cutting tools, surface and subsurface micro cracks, corrosion etc. Therefore, with proper selection of the MQL system and the cutting parameters, it is possible for MQL machining with minimum cost and less quantity of coolant to obtain better conditions, in terms of lubricity, tool life, cutting temperature and surface finish. The findings of this study show that MQL with nano fluid can substitute the flood lubrication for better surface finish.

scholarly journals Investigation into Performance of Multilayer Composite Nano-Structured Cr-CrN-(Cr0.35Ti0.40Al0.25)N Coating for Metal Cutting Tools

Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 447 ◽  
Author(s):  
Sergey Grigoriev ◽  
Alexey Vereschaka ◽  
Alexander Metel ◽  
Nikolay Sitnikov ◽  
Filipp Milovich ◽  
...  
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Constructional Steel ◽  
Wear Process ◽  
Layered Architecture ◽  
Process Pattern ◽  
Resistant Layer ◽  
Cutting Speeds

This paper deals with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating. It has a three-layered architecture with a nano-structured wear-resistant layer. The studies involved the investigation into the microstructure (with the use of SEM and TEM), elemental and phase composition (XRD and SAED patterns), wear process pattern in scratch testing, crystal structure, as well as the microhardness of the coating. Cutting tests of tools with the above coating were carried out in dry turning of steel 1045 at cutting speeds of vc = 200, 250, and 300 m·min−1. The comparison included uncoated tools and tools with the commercial TiN and (Ti,Al)N coatings with the same thickness. The tool with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating showed the longest tool life at all the cutting speeds under consideration. Meanwhile, a tool with the coating under study can be recommended for use in turning constructional steel at the cutting speed of vc = 250 m·min−1. At this cutting speed, a tool shows the combination of a rather long tool life and balanced wear process, without any threat of catastrophic wear.

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.

Turning of SAE 1050 Steel With Vegetable Base Cutting Fluid

2012 ◽  
Author(s):  
Rosemar Batista da Silva ◽  
Álisson Rocha Machado ◽  
Déborah de Oliveira Almeida ◽  
Emmanuel O. Ezugwu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Manufacturing Companies ◽  
Machining Performance ◽  
Increase Tool Life

The study of cutting fluid performance in turning is of great importance because its optimization characteristics has associated benefits such as improved tool life and overall quality of machined components as well as reduction in power consumption during machining. However, there are recent concerns with the use of cutting fluids from the environmental and health standpoints. Since environmental legislation has become more rigorous, the option for “green machining” attracts the interest of several manufacturing companies. It is important to consider the cost of machining which is associated with tool wear, depending on the cutting environment. The use of vegetable oil may be an interesting alternative to minimize the health and environmental problems associated with cutting fluids without compromising machining performance. This paper presents a comparative study of mineral and vegetable cutting fluids in terms of tool wear after turning SAE 1050 steel grade with cemented carbide cutting tools. Constant depth of cut of 2mm and variable cutting speed (200 and 350 m/min) and feed rate (0.20 and 0.32 mm/rev) were employed. Test results suggest that is possible to achieve improvement in machinability of the material and increase tool life by using vegetable cutting fluid during machining. Tool life increased by about 85% when machining with vegetable-based fluids compared to mineral-based fluids. Analysis of the worn tools, however, revealed a more uniform wear on the worn flank face when machining with mineral-based fluids.

Tool Wear Investigation on Dry Electrostatic Cooling in Turning Titanium Alloy Ti6Al4V

2010 ◽  
Vol 97-101 ◽  
pp. 2058-2061 ◽  
Author(s):  
Hui Wang ◽  
Rong Di Han ◽  
Yang Wang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Set Up ◽  
Titanium Alloy Ti6al4v ◽  
Emulsion Oil

The machinability of Titanium Alloy Ti6Al4V is poor, the traditional methods to machining is application of cutting fluids with the active additives which cause environmental pollution and health problems. In this paper, the dry electrostatic cooling was applied instead of cutting fluid for the aim of green cutting Ti6Al4V. The ionized device and gas supply system was set up, the effects of dry electrostatic cooling, emulsion oil and dry cutting on tool wear have been examined in turning of Ti6Al4V with carbide tools YG8, the curve between tool flank wear and cutting time was proposed, and the equation between cutting speed and tool life was set up. The results of experiments indicated that application of dry electrostatic cooling reduced the tool wear and increased the tool life. The research results show that clean production was achieved in metal cutting associated with dry electrostatic cooling.

Experimental Investigations on Cryogenic Cooling in Drilling of Aluminium Alloy

2014 ◽  
Vol 592-594 ◽  
pp. 316-320 ◽  
Author(s):  
N. Govindaraju ◽  
Ahmed L. Shakeel ◽  
M. Pradeepkumar
Keyword(s):  
Aluminium Alloy ◽  
Metal Cutting ◽  
Thrust Force ◽  
Harmful Effect ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cryogenic Cooling ◽  
Cutting Fluid ◽  
Experimental Investigations ◽  
Drilling Depth

The usage of a conventional cutting fluid in the metal cutting operations gives harmful effect for environment and to the operator’s health. In this study, experimental investigations were carried out in a drilling operation on aluminium alloy material using a liquid nitrogen (LN2) coolant. The variables in the experiment were, cutting speed and feed, the drilling depth was maintained constant. For each feed rate (0.02, 0.05 & 0.08 mm/rev) three holes were drilled for cutting speeds 110, 130 & 150 m/min. The cutting temperature and thrust force were recorded. The cutting temperature and thrust force were reduced, when cutting speed was increased. The hole quality parameters like cylindricity, circularity and perpendicularity were analyzed using CMM.

Recent Development of Parameter Optimization for Metal Cutting and Grinding Processes

2013 ◽  
Vol 652-654 ◽  
pp. 2218-2221 ◽  
Author(s):  
Li Bao An ◽  
Chun Guang Lu
Keyword(s):  
Parameter Optimization ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Optimization Of Cutting Parameters

Metal cutting indicates a specific category of processes in which unwanted material is removed from workpeice by single- or multi-point cutting tools for making products meeting prescribed specifications. Parameter optimization in metal cutting plays an important role in satisfying quality requirements of machined parts at low production cost or time. It requires optimal selection of cutting speed, feed rate, depth of cut, and the number of passes. A brief review of recent progress on the optimization of cutting parameters is introduced in the present work. Some new machining practices expending in recent years are involved including hard turning, dry cutting, high speed machining, machining of difficult-to-machine materials and composites. Modeling skills for creating optimization models and optimization techniques for solving optimal or near-optimal solutions are summarized and analyzed.

Observations on the Angle Relationships in Metal Cutting

1959 ◽  
Vol 81 (3) ◽  
pp. 263-279 ◽  
Author(s):  
D. M. Eggleston ◽  
R. Herzog ◽  
E. G. Thomsen
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Minimum Energy ◽  
Cutting Tools ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Shear Plane ◽  
Energy Criterion ◽  
The Hill

Orthogonal-cutting experiments using SAE 1112 free-cutting steel, 2024-T4 and 6061-T6 aluminum alloys, and alpha-brass (85 Cu-15 Zn) at feeds of 0.002 to 0.010 ipr, were performed on a lathe with 18-4-1 high-speed-steel cutting tools. The mean cutting speeds and rake angles for SAE 1112 varied from 33.7 to 170.8 fpm and 5 to 40 deg, respectively, while the remainder of the alloys were tested at conditions yielding a continuous chip without a built-up edge at speeds ranging from approximately 470 to 790 fpm. It was found that the angle λ between the shear plane and the resultant tool force R was only approximately constant for each test condition and varied with cutting speed. Hence the equation λ = ϕ + β − α = const and the linear relationship between ϕ and β − α are only approximately satisfied. Furthermore, neither the Ernst and Merchant minimum-energy criterion, nor the Lee and Shaffer nor the Hill ideal plastic-solid solution, is in agreement with all the experimental observations.

Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

2019 ◽  
Vol 947 ◽  
pp. 160-166
Author(s):  
Nutrada Khumjeen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Turning Process ◽  
Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

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