Experimental Investigation on the Effect of Tool Geometry and Cutting Conditions Using Tool Wear Prediction Model for End Milling Process

2014 ◽  
Vol 13 (01) ◽  
pp. 41-54 ◽  
Author(s):  
S. Kalidass ◽  
P. Palanisamy
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Condition ◽  
Machining Parameter

Tool wear of a cutting tool has a significant impact on the tool life and surface quality of the finished product. Tool wear is influenced by many factors such as cutting parameters, tool geometry, coating type, work piece material, chatter, and cutting condition. In the present work, the design of experiments (DOE) technique has been used for four factors at five levels to conduct experiments. Tool wear is taken as the response variable measured during end milling, while helix angle, spindle speed, feed and depth of cut are taken as the input parameters. The material and tool selected for this study are AISI 304 stainless steel and uncoated solid carbide end mill cutter respectively. The tool wear was measured using tool maker's microscope. The experimental values are used in six sigma software for finding the coefficients to develop the regression model. The direct and interaction effect of the machining parameter with tool wear were analyzed using contour graphs, which helped to select process parameters for reducing tool wear and also ensure quality of milling.

Identification of Optimum Heating Temperature in Thermal Assisted Turning of Stainless Steel Using Three Different Approaches

2013 ◽  
Vol 393 ◽  
pp. 194-199 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Noor Hawa B. Mohamad Rasdi ◽  
Khairus Syakirah B. Mahmud ◽  
Abdul Hakam B. Ibrahim ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Heating Temperature ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Work Piece ◽  
Optimum Temperature ◽  
Main Concept

Thermal or heat assisted machining is used to machine hard and difficult-to-machine materials such as Inconel and Titanium alloys. The main concept is that localized surface heating of the work-piece reduces the yield strength of the material significantly, making it amenable to plastic deformation and machining. Thus, heat assisted machining has been used for over a century. However, the heating technique and temperature are very much dependent on the type of working material. Therefore, a multitude of heating techniques has been applied over the years including Laser Assisted Machining (LAM) and Plasma Enhanced Machining (PEM) in the industry. But such processes are very expensive and have not been found in wide scale applications. The authors of the current research have therefore looked into the application of a simple Tungsten Inert Gas (TIG) welding setup to perform heat assisted turning of AISI 304 Stainless Steel. Such welding equipment is relatively cheap and available. Also, stainless steel is perennially used in the industry for high strength applications. Hence, it is very important to determine with optimal cutting temperature when applying a TIG setup for heat assisted machining of stainless steel. This paper describes three separate techniques for determining the optimum temperature. All three processes applied the same experimental setup but used different variables for evaluating the best temperature. The first process used vibration amplitude reduction with increment in temperature to identify the desired temperature. The second process used chip shrinkage coefficient to locate the same temperature. And finally, the third process investigated tool wear as a criterion for determining the optimum temperature. In all three cases the three primary cutting parameters: cutting speed, feed, and depth of cut, were varied in the same pattern. The results obtained from all three approaches showed that 450oC was undoubtedly the best temperature for heat assisted machining of stainless steel.

Dry Machining of Brass Using Titanium Carbonitride (TiCN) Coated Tool

2013 ◽  
Vol 372 ◽  
pp. 495-500
Author(s):  
Tasnim Firdaus Ariff ◽  
Mohd Syahidan Kamarudin ◽  
Mohd Amiruddin Haron
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Cutting Parameters ◽  
Titanium Carbonitride ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Machining ◽  
Wear Rates ◽  
Optimum Cutting ◽  
The Cost

Dry machining is environmentally friendly, clean and safe to be performed. Regardless of decreasing tool life due to lack of lubricants, choosing dry machining over wet machining may be a wiser choice since the cost of purchasing and disposing the cutting fluids can contribute to a higher cost. Wear rates, tool wear intensities and material removal rates (MRR) of TiCN coated tools using both dry and traditional wet machining on brass were studied with the aim in finding the optimum cutting condition from four different cutting speeds (207, 279, 372 and 498 m/min) with two sets of cutting parameters; depth of cut and feed rate (d = 0.1 mm, f = 0.2 mm/rev and d = 0.2 mm, f = 0.4 mm/rev). Temperatures at the tool-chip interface were measured to analyze the effects of temperature rise during dry machining. Cost analysis on machining cost per piece between dry and wet machining was performed. The optimum cutting condition for wet and dry machining of brass using TiCN coated cutting tool was found to be 498 m/min at d = 0.2 mm, f = 0.4 mm/rev. The tool tip temperature obtained from dry machining did not influence tool wear since the temperature rise is quite similar to the wet machining temperatures. The machining for the dry machining reduced to about 25-76% per piece when compared with wet machining.

Optimization of the Process Parameters in Milling of Aluminum Alloys

2020 ◽  
Vol 896 ◽  
pp. 293-298
Author(s):  
Nicolae Craciunoiu ◽  
Emil Nicusor Patru ◽  
Adrian Sorin Rosca ◽  
Dumitru Panduru ◽  
Marin Bica
Keyword(s):  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Experimental Conditions ◽  
Milling Parameters

In order to control the temperature during milling process of aluminum alloys and keeping as minimum as possible, the choice of the cutting parameters and their optimization is very important, both for the tool wear but also for the surface quality of machined surface. The main purpose of this paper is to find the optimum values of the milling parameters (rotational speed and depth of cut) so that the minimum value for the temperature to be obtained. Using adequate experimental conditions with contact measurements techniques (thermocouple K-type) carried out on the some types of aluminum alloys and the appropriate statistical instruments, the most influencing cutting parameters and their values on the cutting temperature can be found. The results are presented both analytical and graphical.

Optimal flank wear in turning of Inconel 625 super-alloy using ceramic tool

2016 ◽  
Vol 232 (2) ◽  
pp. 208-216 ◽  
Author(s):  
M Jahanbakhsh ◽  
A Akhavan Farid ◽  
Mohammad Lotfi
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Flank Wear ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Cutting Condition

Rapid tool wear is one of the major machinability aspects of nickel-based super alloys. In this article, the effect of cutting parameters on material removal rate and tool wear of a whisker ceramic insert in turning of Inconel 625 was examined. Optical microscope and scanning electron microscope were applied to measure and study tool wear mechanism. Response surface method was used to develop a mathematical model which confirmed by experimental tests. The statistical analysis done by analysis of variance showed that depth of cut is the most effective factor on the tool wear. Experiments showed that increment of feed rate had an insignificant effect on the progress of flank wear, and it is an important controlling factor when material removal rate is considered as a desired output. Finally, optimized cutting condition is presented in this work.

Tool Wear and Surface Integrity in End Milling of Ti6Al4V with Polycrystalline Diamond Tools

2013 ◽  
Vol 820 ◽  
pp. 134-137
Author(s):  
Wen Cheng Pan ◽  
Bramha Kondaiah ◽  
Song Lin Ding ◽  
John Mo
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
End Milling ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Strong Relationship ◽  
Cutting Parameters ◽  
Work Piece ◽  
Machine Material

Titanium is a difficult-to-machine material due to its low heat conductivity and high chemical reactivity. It creates high tool wear and causes low machining efficiency. The strong relationship cutting forces between and tool wear and surface integrity of work piece makes it necessary to study the effect of dynamic cutting force on cutting tools to analyse the wear propagation and tool life. This paper investigates the tool wear on Polycrystalline Diamond (PCD) cutters in milling Ti-6Al-4V and analyses workpiece surface quality. Based on the experimental results of slot milling, cutting parameters that yields best surface finish were found.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Influence of Cutting Conditions on Surface and Sub-Surface Quality of High Speed Dry End Milling Ti-6Al-4V

2014 ◽  
Vol 67 (3) ◽  
Author(s):  
H. Safari ◽  
S. Izman
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Surface Quality ◽  
High Speed ◽  
End Milling ◽  
Cutting Parameters ◽  
Machining Process ◽  
Surface Alteration ◽  
Cutting Speeds

Surface quality is one of the most critical restraints for determining cutting parameters and selecting of machining process in metal cutting process. In this study, the effects of cutting parameters and tool wear on the surface and sub-surface quality of high speed dry end milling Ti-6Al-4V were investigated. PVD Coated carbide tools were used under different high cutting speeds and feed rates. The quality of the machined surface and corresponding alteration on the sub-surface and entry/exit edges were characterized through scanning electron microscopy. The results showed that the better surface quality was obtained when machining at higher cutting speeds and feed rates. High speed dry end milling using the worn tool causes to plastic deformation of the alloy which is resulted in developing the lamellae on the surface and causing poor surface finish. Worn tools with the uniform tool wear land generated better surface quality compare to those with chipping and flaking on the tool edge surface. Tool wear is suggested as the other contributing factor in developing entry and exit edge damages. The results of sub-surface alteration measurement revealed that the worn tool enhanced the sub-surface alteration resulted in 45% increase in plastic deformation compare to the new tool.

Energy conscious cryogenic machining of Ti-6Al-4V titanium alloy

2016 ◽  
Vol 232 (10) ◽  
pp. 1690-1706 ◽  
Author(s):  
Alborz Shokrani ◽  
Vimal Dhokia ◽  
Stephen T Newman
Keyword(s):  
Energy Consumption ◽  
Tool Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cryogenic Cooling ◽  
Depth Of Cut ◽  
Cryogenic Machining ◽  
Coolant Pump ◽  
Cutting Speeds

Manufacturing and, in particular, machining are responsible for a significant portion of global industrial energy consumption (25%). Previous research has shown that precise selection of cutting parameters can improve the energy consumption of machining processes. Cryogenic machining has attracted significant attention for improving the machinability of difficult-to-machine materials while also eliminating the environmental and health issues associated with the use of cutting fluids. Despite the advantages, there is a considerable research gap in cryogenic milling operations. This article investigates the effect of cryogenic cooling using liquid nitrogen in end milling of Ti-6Al-4V. A robust and rigorous methodology was developed and a series of machining experiments were conducted using a combination of cutting parameters repeated at dry, flood and cryogenic cooling environments. The investigations indicated that cryogenic cooling considerably reduce tool wear when compared to dry and flood cooling while allowing for using higher cutting speeds. The cutting tool used for cryogenic machining at 200 m/min cutting speed, 0.03 mm/tooth feed rate and 5 mm depth of cut showed minimum flank wear. Furthermore, the investigations demonstrated that using the machine’s coolant pump in flood cooling resulted in higher power and energy consumption than dry and cryogenic cooling. This article clearly shows that higher material removal rates are required in order to minimise specific machining energy. Therefore, since cutting speed is limited in dry machining, cryogenic machining is the most favourable as higher cutting speeds can be used. Using cryogenic machining at 200 m/min cutting speed resulted in an 88% reduction in energy consumption of the machine tool as compared to flood cooling at 30 m/min while minimum tool wear (10 µm) was detected. This clearly demonstrates the significant capabilities of cryogenic machining when compared with more conventional machining approaches.

Reducing Tool Wear in CNC End Milling Operation Using Progressive Feed Rate

2014 ◽  
Vol 592-594 ◽  
pp. 716-723
Author(s):  
K.S. Badrinathan ◽  
L. Karunamoorthy
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cnc End Milling

This study focuses on the effect of cutting parameters on the tool wear in a CNC end milling operation. Major factors which influence the tool wear are spindle speed, feed rate and depth of cut. Conventionally constant feed rate is used. In this work a concept of progressive feed rate is introduced. AISI 1045 steel has been chosen as it is widely used in manufacturing. Design of Experiments (DOE) technique was adopted to conduct the experiments. Experiments were conducted for both the existing and the proposed feed rate method and the tool wear was compared. A statistical model was developed using Design Expert software. The predicted values were compared with the experimental values and were found to be in close agreement. The model adequacy was checked using ANOVA technique.

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