On the Tribological Effectiveness of Controlled Cutting Fluid Application in Machining With Coated Tools

2005 ◽  
Author(s):  
Anshu D. Jayal ◽  
A. K. Balaji
Keyword(s):  
Tool Material ◽  
Chip Morphology ◽  
Cutting Fluid ◽  
Machining Performance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Application Methods ◽  
The Individual ◽  
1045 Steel ◽  
Coated Carbide

Environmental and economic pressures are causing reevaluation of the use of Cutting Fluids (CFs) in machining operations, leading to recent efforts in promoting dry, as well as minimal quantity of lubricant (MQL), machining. This paper presents an experimental investigation into the effects of different CF application methods on various machining performance measures under modern cutting conditions using uncoated and coated cemented tungsten carbide tools. CF effects under dry, flood, and MQL conditions, were gauged through their influence on cutting forces, tool temperatures, tool-chip interfacial friction, and chip morphology during machining of AISI 1045 steel using commercially available uncoated, and mono- and multi-layer coated, carbide tools. The results show new trends on the individual cooling and lubricating effects of CF application methods, and the integrated effects of their interactions with tool material, on tribological performance.

Tribological and Thermal Effects of Cutting Fluid Application in Machining With Coated and Grooved Cutting Tools

2005 ◽  
Author(s):  
Anshu D. Jayal ◽  
A. K. Balaji
Keyword(s):  
Cutting Tools ◽  
Chip Morphology ◽  
Cutting Fluid ◽  
Machining Performance ◽  
Chip Breaking ◽  
Tool Coatings ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Application Methods ◽  
1045 Steel

The use of Cutting Fluids (CFs) in machining operations is being increasingly questioned in recent years for environmental and economic reasons, leading to efforts in promoting dry, as well as minimal quantity of lubricant (MQL), machining. However, the tribological effectiveness and thermal aspects of CF action at modern cutting conditions, which not only involve relatively high cutting speeds but also advanced tool coatings and chip-breaking geometric features, need better understanding. This paper presents an experimental investigation into the effects of different CF application methods on various machining performance measures while cutting with commercially available flat-faced, as well as grooved, uncoated and coated cemented tungsten carbide tools. CF effects under dry, flood, and MQL conditions, were gauged through their influence on cutting forces, tool temperatures, tool-chip interfacial contact, and chip morphology during machining of AISI 1045 steel. The results show new trends on the individual cooling and lubricating effects of CF application methods, and the effects of their interactions with the tool coatings and the presence/absence of chip-breaking grooves.

scholarly journals ANALYSIS OF SURFACE ROUGHNESS MILLED OF STEEL AISI 1045 USING X-BAR AND R CONTROL CHART

2020 ◽  
Vol 5 (6) ◽  
pp. 15-23
Author(s):  
Leonardo Geraldo Leite ◽  
Ítalo de Abreu Gonçalves ◽  
Carlos Henrique De Oliveira ◽  
Tarcísio Gonçalves De Brito ◽  
Sandra Miranda Neves ◽  
...  
Keyword(s):  
End Milling ◽  
Roughness Parameter ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Fluid ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide ◽  
End Milling Process

The steel milling AISI 1045 has been gaining prominence in industry in recent years as it allows machined parts to be obtained with low-cost inserts. However, to ensure the final product quality, it is important that the milling for machining procedure be well planned in order to the cutters have their wear minimized in the process, as well as a considerable productivity rate with a zero occurrence of reworked parts or scraps. Thus, this paper presents a study about the quality of the machined surface on the end milling process of AISI 1045 steel using titanium nitride (TiN) coated carbide inserts, optimized for a combined design, using Design of Experiments (DOE). Statistical Process Control (SPC) is applied to analyze the process variations using X-bar and R control charts. The objective of this study is to identify the optimal combination of the input setup such as cutting speed (Vc), feed per tooth (fZ), work penetration (ae) and machining depth (ap) that is capable of minimize the process variation. The response measured is the roughness parameter Ra, observed under the influence of cutting fluid, tool wear, concentration and flow of the cutting fluid as noise. The obtained result was the stability of the Ra roughness for the AISI 1045 steel in end milling process, which is not influenced by noise variables due to Robust Parameter Design used in this study

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

2011 ◽  
Vol 223 ◽  
pp. 286-295 ◽  
Author(s):  
Cédric Courbon ◽  
Tarek Mabrouki ◽  
Joël Rech ◽  
Denis Mazuyer ◽  
Enrico D'Eramo
Keyword(s):  
Heat Flux ◽  
Hot Spot ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Contact Length ◽  
Dry Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The present work proposes to enhance the thermal interface denition in Finite Element (FE) simulations of machining. A user subroutine has been developed in Abaqus/Explicit © to implement a new experimentally-based heat partition model extracted from tribological tests. A 2D Arbitrary-Lagragian-Eulerian (ALE) approach is employed to simulate dry orthogonal cutting of AISI 1045 steel with coated carbide inserts. Simulation results are compared to experimental ones over a whole range of cutting speeds and feed rates in terms of average cutting forces, chip thickness, tool chip contact length and heat flux. This study emphasizes that heat transfer and temperature distribution in the cutting tool are drastically in uenced by the thermal formulation used at the interface. Consistency of the numerical results such as heat flux transmitted to the tool, peak temperature as well as hot spot location can be denitively improved.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

scholarly journals Assessment of CVD- and PVD-Coated Carbides and PVD-Coated Cermet Inserts in the Optimization of Surface Roughness in Turning of AISI 1045 Steel

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5231
Author(s):  
Evandro Paese ◽  
Martin Geier ◽  
Fabiano R. Rodrigues ◽  
Tadeusz Mikolajczyk ◽  
Mozammel Mia
Keyword(s):  
Surface Quality ◽  
Material Removal Rate ◽  
Vapor Deposition ◽  
Material Removal ◽  
Removal Rate ◽  
Controllable Factors ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

In this study, an experimental and statistic investigation approach based on analysis of variance (ANOVA) and response surface methodology (RSM) techniques was performed to find the significant main effects and two-factor interaction effects and to determine how the controllable factors such as cutting speed, feed rate, depth of cut (DOC), tool nose radius, substrate and coating method of cutting tools influence surface quality in turning of AISI 1045 steel. The first optimal or near-optimal conditions for the quality of the generated surface and the second ones, including maximum material removal rate, were established using the proposed regression equations. The group mean roughness of the turned workpieces was lower from using chemical vapor deposition (CVD)-coated carbide inserts than the group means of other types of inserts; however they could not achieve the specific lowest roughness. The physical vapor deposition (PVD)-coated carbide and cermet inserts achieved the best surface quality when the specific combinations within the range interval of controllable factors were used in the experiment, showing that they may be applied to finish turning processes or even to particular high material removal rate conditions associated with the lowest roughness.

Identification of a Friction Model at the Tool-Chip-Workpiece Interface in Dry Machining of a AISI 1045 Steel With a TiN Coated Carbide Tool

2011 ◽  
Vol 133 (4) ◽  
Author(s):  
Hamdi Ben Abdelali ◽  
Cedric Courbon ◽  
Joël Rech ◽  
Wacef Ben Salem ◽  
Abdelwaheb Dogui ◽  
...  
Keyword(s):  
Friction Model ◽  
Carbide Tool ◽  
Dry Machining ◽  
Sliding Velocity ◽  
Partition Model ◽  
Heat Partition ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The characterization of frictional phenomena at the tool-chip-workpiece interface in metal cutting remains a challenge. This paper aims at identifying a friction model and a heat partition model at this interface during the dry cutting of an AISI1045 steel with TiN coated carbide tools. A new tribometer, based on a modified pin-on-ring system, has been used in order to reach relevant values of pressures, temperatures, and sliding velocities. Additionally a 3D Arbitrary Lagrangian Eulerian model (A.L.E.) numerical model simulating the frictional test has been developed in order to extract local parameters around the spherical pin, such as average contact pressure, average local sliding velocity, and average contact temperature, from experimental macroscopic measurements. A large range of sliding velocities [0.083–5 m/s] has been investigated. It has been shown that friction coefficient and heat partition coefficient are mainly dependant on local sliding velocity at the interface. Three friction regimes have been identified. These experimental and numerical results provide a better understanding of the tribological phenomena along the tool-chip-workpiece interfaces in dry machining of an AISI 1045 steel with a TiN coated carbide tool. Finally a new friction model and heat partition model has been developed for implementation in a numerical cutting model.

High Speed Machining of Hardened AISI 1045 Steel

2016 ◽  
Vol 861 ◽  
pp. 63-68 ◽  
Author(s):  
Xue Ping Zhang ◽  
Shu Biao Wu ◽  
Zhen Qiang Yao ◽  
Li Feng Xi
Keyword(s):  
High Speed ◽  
Shear Bands ◽  
Chip Morphology ◽  
Machining Parameters ◽  
Chip Breaker ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
High Feed ◽  
Serrated Chips ◽  
1045 Steel

Hardened AISI 1045 steel implemented in machine tool spindle was previously ground using grinding operation. This research aims to address the feasibility of hard turning AISI 1045 using PCBN tool with chip breaker under dry condition. Chip morphology, cutting force and temperature were measured, analyzed and correlated with machining parameters. Experimental results demonstrate that serrated chips are generated at high speeds, high feed rate is an assistant to promote serrated chips, and chip breaker can help break chip into acceptable lengths. Cutting forces were characterized with periodic fluctuation along three directions as chips are serrated. Temperature at machined zone can reach as high as 1200°C, which indicates that adiabatic shear bands can be successfully achieved during the machining of hardened AISI 1045 steel without applying lubricants.

A Parametric Study of the Modeling of Orthogonal Machining Using the Smoothed Particle Hydrodynamics Method

2015 ◽  
Author(s):  
Chinmay S. Avachat ◽  
Harish P. Cherukuri
Keyword(s):  
Finite Element ◽  
Smoothed Particle Hydrodynamics ◽  
Chip Morphology ◽  
Machining Processes ◽  
Orthogonal Machining ◽  
Particle Hydrodynamics ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Smoothed Particle ◽  
1045 Steel

Modeling machining processes with conventional finite element methods (FEM) is challenging due to the severe deformations that occur during machining, complex frictional conditions that exist between the cutting tool and the workpiece, and the possibility of self contact due to chip curling. Recently, the Smoothed Particle Hydrodynamics (SPH) method has emerged as a potential alternative for modeling machining processes due to its ability to handle severe deformations while avoiding mass and energy losses encountered by traditional FEM. The method has been implemented in several commercial finite element packages such as ABAQUS and LS-DYNA for solving problems involving localized severe deformations. Numerous control parameters are present in a typical SPH formulation. The purpose of this work is to evaluate the effect of the three most important parameters, namely, the smoothing length, particle density, and the type of SPH formulation. The effects of these parameters on the chip morphology and stress distribution in the context of orthogonal machining of AISI 1045 steel are investigated. The LS-DYNA finite element package along with Johnson-Cook material model is used for this purpose. Results from the parametric study are presented and compared with the previously reported results in the literature. In addition, the sensitivity of chip morphology and stresses to Johnson-Cook parameters for AISI 1045 steel is also investigated by considering five different sets of values reported in the literature for this steel.

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