Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

2017 ◽  
Vol 16 (03) ◽  
pp. 237-261 ◽  
Author(s):  
T. Sampath Kumar ◽  
S. Balasivanandha Prabu ◽  
T. Sorna Kumar
Keyword(s):  
Surface Roughness ◽  
Alloy Steel ◽  
Surface Finish ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Coated Carbide

In the present work, the performances of TiAlN-, AlCrN- and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN- and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi’s approach is used to obtain the best turning parameters, namely cutting speed ([Formula: see text]), feed rate ([Formula: see text]) and depth of cut ([Formula: see text]), in order to have a better surface finish and minimum tool flank wear. An orthogonal array (L[Formula: see text] was used to conduct the experiments. The results show that the AlCrN/TiAlN-coated cutting tool provided a much better surface finish and minimum tool flank wear. The minimum tool flank wear and minimum surface roughness were obtained using AlCrN/TiAlN-coated tools, when [Formula: see text][Formula: see text]m/min, [Formula: see text][Formula: see text]mm/rev and [Formula: see text][Formula: see text]mm.

Optimization of Surface Roughness and Flank Wear in Turning SCM440 Alloy Steel Using Taguchi Method

2014 ◽  
Vol 592-594 ◽  
pp. 641-646
Author(s):  
R. Thirumalai ◽  
S. Srinivas ◽  
T. Vinodh ◽  
A.L. Kowshik Kumar ◽  
M. Kishore Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Alloy Steel ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Regression Equations ◽  
Sem Images ◽  
Coated Carbide ◽  
Cut Surface

The purpose of this research paper is focused on the analysis of optimum cutting conditions to get minimum surface roughness and minimal flank wear in turning SCM 440 alloy steel by Taguchi method. L9orthogonal array is designed to conduct the experiments. Experiments are conducted on supercut 5XL Lathe using coated carbide tool. The process parameters are cutting speed, feed and depth of cut. Surface Roughness and Flank wear are selected as the responses. Surface Roughness is measured using Mitutoyo Surface roughness tester and Flank wear is predicted using SEM images after the experiments. The results are analyzed using analysis of variance (ANOVA) method. The regression equations for the responses are determined and the probability plots are plotted and found satisfactory. The R-squared values are also calculated using analysis of variances and it is found that these values are close to the proximity level and satisfactory. Taguchi method is used to analyze the dominating parameters in minimization of surface roughness and minimization of flank wear.,

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Optimization of Surface Roughness by Using Different Cutting Tools for Aluminum Alloy 6063

2020 ◽  
Vol 17 (2) ◽  
pp. 961-966
Author(s):  
Allina Abdullah ◽  
Afiqah Azman ◽  
B. M. Khirulrizwan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Optimum Parameter ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Numerical Control ◽  
Depth Of Cut

This research outlines an experimental study to determine the optimum parameter of cutting tool for the best surface roughness (Ra) of Aluminum Alloy (AA) 6063. For the experiment in this research, cutting parameters such as cutting speed, depth of cut and feed rate are used to identify the effect of both cutting tools which are tungsten carbide and cermet towards the surface roughness (Ra) of material AA6063. The machining operation involved to cut the material is turning process by using Computer Numerical Control (CNC) Lathe machine. The experimental design was designed by Full Factorial. The experiment that had been conducted by the researcher is 33 with 2 replications. The total number of the experiments that had been run is 54 runs for each cutting tool. Thus, the total number of experiments for both cutting tools is 108 runs. ANOVA analysis had been analyzed to identify the significant factor that affect the Ra result. The significant factors that affect the Ra result of AA6063 are feed rate and cutting speed. The researcher used main effect plot to determine the factor that most influenced the surface roughness of AA6063, the optimum condition of surface roughness and the optimum parameter of cutting tool. The factor that most influenced the surface roughness of AA6063 is feed rate. The optimum condition of surface roughness is at the feed rate of 0.05 mm/rev, cutting speed of 600 rpm and depth of cut of 0.10 mm. While the optimum parameter of cutting tool is cermet insert with the lowest value of surface roughness (Ra) result which is 0.650 μm.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

scholarly journals Influence of the Cutting Parameters on the Surface Roughness when Machining Hardened Steel with Ceramic and PCBN Cutting Tools

2015 ◽  
Vol 13 ◽  
pp. 19-22 ◽  
Author(s):  
Gabriel Benga ◽  
Danut Savu ◽  
Adrian Olei
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Bearing Steel ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Cutting Regimes

The paper presents the influence of various cutting regimes on the surface roughness, when a hardened bearing steel has been machined using both ceramic and PCBN cutting tools. There were used different cutting conditions varying cutting speed, feed rate and depth of cut in order to determine the influence of each cutting parameter on the surface finish.

scholarly journals Experimental Study on Surface Roughness and Flank Wear in Turning of Nimonic C263 under Dry Cutting Conditions

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
J. Francis Xavier ◽  
B. Ravi ◽  
D. Jayabalakrishnan ◽  
Chakaravarthy Ezilarasan ◽  
V. Jayaseelan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Controlling Factors ◽  
Average Error ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Machined Surface

Aircraft component manufacturing sector is looking for high precision machining in aircraft components. The present work explores the operability of green manufacturing of Nimonic C263 using dry turning. Nimonic C263 is tough to turn owing to its inherent quality like low conductivity and more work hardening. Therefore, in order to improve this machined surface/integrity, the controlling factors were optimized based on desirability approach for minimum of surface roughness and flank wear during turning of this alloy using CBN insert. L27 orthogonal array was chosen to carry out the experiment. The effects of controlling factors, such as cutting speed ( V ), feed rate ( S ), and cut penetration/depth of cut ( a p ) on the outputs, were also explored. The feed rate was a major impact to affect surface finish and flank wear. The average error percentage between the experimental and RSM models for surface finish was 4.76 percent and 2.79 percent for flank wear.

scholarly journals Optimizing Multi-Response Parameters in Turning of AISI1040 Steel Using Desirability Approach

2019 ◽  
Vol 4 (4) ◽  
pp. 905-921
Author(s):  
Srinu Gugulothu ◽  
Vamsi Krishna Pasam
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Multi Objective ◽  
Single Objective

In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.

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.

TOOL LIFE PERFORMANCE OF COATED CARBIDE TOOL ON TITANIUM ALLOY EXTRA LOW INTERSTITIALS

2015 ◽  
Vol 77 (1) ◽  
Author(s):  
R. Zuraimi ◽  
M. A. Sulaiman ◽  
T. Joseph Sahaya Anand ◽  
E. Mohamad ◽  
C. H. Che Haron
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Chemical Vapor ◽  
Corrosion Property ◽  
Depth Of Cut ◽  
Coated Carbide

The Titanium alloys (Ti-6Al-4V) has been employed in a variety of applications, particularly in the aerospace, automotive, medical and chemical industries, primarily because of its high strength to weight ratio, high resistance to fracture, and exceptional anti-corrosion property. However, Ti-6Al-4V cannot be easily machined even at a high temperature as it has a low thermal conductivity and low elastic modulus, and may react chemically with the coating on the cutting tool. The objective of this study was to investigate the cutting tool life performance in the turning of Ti-6Al-4V Extra Low Interstitials (ELI) using a Chemical Vapor Deposition (CVD) carbide cutting tool in dry conditions. The Factorial method was used as the basis for the experimental design of this study. A factorial design with two levels was chosen for the arrangement of the cutting parameters, which comprised a cutting speed of between 100 to 140 m/min, a feed rate of between 0.15 to 0.20 mm/rev, and a fixed depth of cut of 0.35 mm. A three-axis microscope was used to measure the flank wear for every 20 mm on the workpiece until the ISO criterion was arrived at by the flank wear (Vb). The results indicated that the maximum tool life of 20.68 minutes was achieved at a cutting speed of 100 m/min and a feed rate of 0.15 mm/rev.

Comparison and optimization of PVD and CVD method on surface roughness and flank wear in hard-machining of DIN 1.2738 mold steel

Sensor Review ◽  
2019 ◽  
Vol 39 (1) ◽  
pp. 24-33 ◽  
Author(s):  
Fuat Kara ◽  
Burak Öztürk
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Parameters ◽  
Quadratic Regression ◽  
Content Type ◽  
Coated Carbide

Purpose This paper aims to examine the performance of the machining parameters used in the hard-turning process of DIN 1.2738 mold steel and identify the optimum machining conditions. Design/methodology/approach Experiments were carried out via the Taguchi L18 orthogonal array. The evaluation of the experimental results was based on the signal/noise ratio. The effect levels of the control factors on the surface roughness and flank wear were specified with analysis of variance performed. Two different multiple regression analyses (linear and quadratic) were conducted for the experimental results. A higher correlation coefficient (R2) was obtained with the quadratic regression model, which showed values of 0.97 and 0.95 for Ra and Vb, respectively. Findings The experimental results indicated that generally better results were obtained with the TiAlN-coated tools, in respect to both surface roughness and flank wear. The Taguchi analysis found the optimum results for surface roughness to be with the cutting tools of coated carbide using physical vapor deposition (PVD), a cutting speed of 160 m/min and a feed rate of 0.1 mm/rev, and for flank wear, with cutting tools of coated carbide using PVD, a cutting speed of 80 m/min and a feed rate of 0.1 mm/rev. The results of calculations and confirmation tests for Ra were 0.595 and 0.570 µm, respectively, and for the Vb, 0.0244 and 0.0256 mm, respectively. Developed quadratic regression models demonstrated a very good relationship. Originality/value Optimal parameters for both Ra and Vb were obtained with the TiAlN-coated tool using PVD. Finally, confirmation tests were performed and showed that the optimization had been successfully implemented.

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