Machinability Assessment in High Speed Turning of High Strength Temperature Resistant Superalloys

2019 ◽  
Vol 18 (04) ◽  
pp. 595-623
Author(s):  
Raju Pawade ◽  
Avinash Khadtare ◽  
Dhanashree Dhumal ◽  
Vishal Wankhede
Keyword(s):  
Surface Roughness ◽  
Shear Strain ◽  
Cutting Force ◽  
Compression Ratio ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
High Strength ◽  
Inconel 600 ◽  
Chip Compression Ratio

The paper discusses the effect of cutting parameters and cutting tool material on chip compression ratio, cutting forces and surface roughness in turning of high strength temperature resistant superalloys (HSTR). The experiments were performed in dry cutting environment on precision CNC lathe with fixed depth of cut of 0.5[Formula: see text]mm. Analytical model is developed to determine chip segmentation frequency, shear angle and shear strain and it is correlated with the machining parameters. The machinability of the selected superalloys is assessed in terms of cutting force, chip compression ratio and surface roughness. It is found from the experimental analysis cutting force magnitude is less at higher cutting speed for all the superalloys. Chip compression ratio is found maximum in case of Inconel 718 due to precipitation hardening of alloy and followed by Inconel 600 and Inconel 800. The chip segmentation frequency is high at lower cutting speed for Inconel 600 due significant strain hardening. Serrated chips are produced during machining of three selected superalloys and it is found that serrated tooth spacing decreases with cutting speed. Shear plane angle increases on cutting speed increases which effect tool workpiece contact length during machining resulted thin, short and snarled chips was produced. From analytical modeling it shows that shear strain decreases with cutting speed which indicate that at higher cutting speed material deformed elastically than plastically. The effect of cutting tool material is observed on the surface roughness. The better surface finish is obtained with coated carbide inserts as compared to ceramic inserts for all the selected superalloys. However, Inconel 800 shows higher surface roughness due to combination of (Ni–Cr–Fe) alloying element which is responsible for carburization of surface layer during machining.

Evaluation of the cutting forces, the surface roughness, and the tool wear characteristics during machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool

2021 ◽  
pp. 095440892110480
Author(s):  
Abdullah Altin
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Signal To Noise ◽  
Ceramic Cutting Tool ◽  
Cutting Speeds

In this research, we had studied the sensitivity for machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool. The investigation had focused on the effects of the cutting speed, on the cutting forces, and on the surface roughness based on Taguchi’s experimental design. The effects of machining parameters were determined using Taguchi’s L27 orthogonal array. The signal-to-noise ratio was calculated for the average of surface roughness and the cutting forces, and the smaller were used to determine the optimal cutting conditions. The analysis of variance and the signal-to-noise ratio had effects on the parameters on both surface roughness and cutting. Three different types of cutting tools had been used in the experiment, namely KYON 4300, KYS 25, and KYS 30. The cutting force of Fz was considered to be the main cutting force. Depending on the material which had been used as cutting tool, the Fz had the lowest cutting speed and the lowest surface roughness with the KYS25 ceramic tool. The cutting force and the surface roughness of KYON 4300 cutting tool had shown better performance than other cutting tools. The flank wear and notch were found to be more effective in the experiments. The long chips were removed at low and medium cutting speeds, while the sawdust with one edge and narrow pitch at high cutting speeds was obtained.

Experimental Study on Cryogenic Cutting of High-Strength Steel with Liquid Nitrogen Cooling

2011 ◽  
Vol 328-330 ◽  
pp. 470-473 ◽  
Author(s):  
Shu Juan Li ◽  
Yong Ke Hu ◽  
Xue Jiang ◽  
Juan Du
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
High Strength Steel ◽  
Cutting Speed ◽  
High Strength ◽  
Dry Cutting ◽  
Chip Breaking ◽  
Cryogenic Cutting ◽  
Hard Cutting ◽  
Made In

As a modern manufacturing technology, cryogenic cutting technology is one of effective ways to improve machining efficiency of hard-cutting materials.With typical hard-cutting materials 35CrMnSiA and 45CrNiMoV high-strength steel as the research object, the comparison experiment between cryogenic cutting and dry cutting of two kinds of high-strength steels was made in this paper. In the changing cutting speed conditions, the cutting force and the surface roughness of two kinds of cutting were measured in this experiment.By changing the length of cutting stroke, the cutter wear of two kinds of cutting was measured, and a comparison of chip-breaking effects was made in the experiment.The experimental results indicate that the cutting force, surface roughness, and tool wear in cutting 35CrMnSiA and 45CrNiMoV high-strength steel under cryogenic condition are reduced, and chip-breaking effect of cryogenic cutting is improved. This may be attributed mainly to improve the machinability of higth-strength steel.

Development and Application of Cermet Cutting Tools Material

2008 ◽  
Vol 375-376 ◽  
pp. 163-167 ◽  
Author(s):  
Tie Fu ◽  
Qi Xun Yu ◽  
Bin Liu ◽  
Yu Guang Wu
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Cutting Force ◽  
High Strength Steel ◽  
Cutting Tool ◽  
Impact Resistance ◽  
Cutting Tools ◽  
Tool Material ◽  
High Strength ◽  
Carbide Insert

In this paper, the development and mechanical, physical properties on cermet cutting tool material are described. By using the cermet insert NT7 developed in recent years and WC based carbide insert YT14, the tool wear, impact and cutting force tests to high strength steel 38CrNi3MoVA (hardened and tempered, HRC36~40) are processed respectively. The results of these tests demonstrate that NT7 cutting tools have better performance on some characteristics, such as wear resistance, tool life and cutting force. And its ability of impact resistance is similar to YT14. These researches will benefit to the poplarizaion and application of cermet cutting tool.

scholarly journals Mechanical Behavior and Microstructure Evolution of Al-5%Cu/TiC Metal Matrix Composite

2020 ◽  
Vol 23 (4) ◽  
pp. 252-255
Author(s):  
L. Ponraj Sankar ◽  
R. Kamalakannan ◽  
G. Aruna ◽  
M.R. Meera ◽  
V. Vijayan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Wear Rate ◽  
Cutting Force ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut

This paper aims to analyze the mechanical characteristics of Al-5%Cu/TiC metal matrix composite, like Surface Roughness, Tensile strength, wear rate of the cutting tool. Copper particles added with aluminum alloy, which can improve the machinability and also reduce wear rate. Typically the titanium materials prefer for its excellent strength during the load-carrying process. Here the TiC particles added with aluminum alloy to increase the composite hardness range. The casting samples are machined by the uncoated carbide cutting tool in CNC. The input turning parameters are speed, depth of cut, feed rate, and cutting force. The surface roughness measurement was done after the machining operation. The build-up edge and microstructure behavior of the tool and workpiece were analyzed using Scanning Electron Microscope. The result shows the more Built-up edge formed at low cutting speed and less build-up edge formed at low cutting speed. The higher cutting force indicates the lower cutting speed of 50m/min. The Build-up edges investigated at lower cutting speed and higher cutting speed. While adding TiC in Al-5%Cu, the elongation of MMC reduced, so it can able to increase the strength of the MMC specimen. Based on these results can able to predict the good mechanical and surface properties of metal matrix composite for the specific application.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Deep Hole Machining with a Small Diameter Drill and Ultrasonic Vibration

2017 ◽  
Vol 749 ◽  
pp. 107-110
Author(s):  
Yuta Masu ◽  
Tomohito Fukao ◽  
Taiga Yasuki ◽  
Masahiro Hagino ◽  
Takashi Inoue
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Small Diameter ◽  
Maximum Amplitude ◽  
Depth Of Cut ◽  
Deep Hole ◽  
Work Material ◽  
Finished Surface

The method of imparting ultrasonic vibration to the cutting tool is known to improve the shape accuracy and finished surface roughness. However, a uniform evaluation of this function in drilling has not been achieved, and the cutting process cannot be checked from the outside. The aim of this study is to investigate the cutting characteristics in deep hole drilling when an ultrasonic vibrator on the table of a machining center provides vibration with a frequency of 20 kHz to the work piece. The ultrasonic vibrations in this system reach the maximum amplitude in the center of the work material. We evaluated the change in finished surface roughness between the section where drilling starts to the point of maximum amplitude with ultrasonic vibration. The main cutting conditions are as follows: cutting speed (V) 12.6 (mm/min); feed rate (s) 30, 60 (mm/rev); depth of cut (t) = 32 (mm); work material, tool steel; cutting tool material, HSS; point angle (σ) 118 (°); and drill diameter (φ) 4 (mm). Lubricant powder was also added to clarify the cutting effect, and compared the condition in which there was no ultrasonic vibration. The results showed that surface roughness at the point of maximum amplitude was better than that with no vibration.

High-Speed Capturing of Stress Distribution of Workpiece under Ultrasonically Assisted Cutting Condition

2014 ◽  
Vol 1017 ◽  
pp. 747-752
Author(s):  
Hiromi Isobe ◽  
Keisuke Hara
Keyword(s):  
Stress Distribution ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Light Emission ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Photoelastic Method ◽  
Intermittent Cutting ◽  
Ultrasonic Vibration Cutting

This paper reports the stress distribution inside the workpiece under ultrasonic vibration cutting (UVC) condition. Many researchers have reported the improvement of tool wear, burr generation and surface integrity by reduction of time-averaged cutting force under UVC condition. However general dynamometers have an insufficient frequency band to observe the processing phenomena caused by UVC. In this paper, stress distribution inside the workpiece during UVC was observed by combining the flash light emission synchronized with ultrasonically vibrating cutting tool and the photoelastic method. Instantaneous stress distribution during UVC condition was observed. Because UVC induced an intermittent cutting condition, the stress distribution changed periodically and disappeared when the tool leaved from the workpiece. It was found that instantaneous maximum cutting force during UVC condition was smaller than quasi-static cutting force during conventional cutting when the cutting speed was less than 500 mm/min.

OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

2021 ◽  
Author(s):  
MAHIR AKGÜN
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Force ◽  
Cutting Speed ◽  
System Optimization ◽  
Gray Relational Analysis ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Significance Level ◽  
Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

Research on Deep-hole Drilling Quality of High-strength Steel With Slender Gun Drill

2021 ◽  
Author(s):  
Jiabin Liang ◽  
Li Jiao ◽  
Pei Yan ◽  
Minghui Cheng ◽  
Tianyang Qiu ◽  
...  
Keyword(s):  
Cutting Force ◽  
High Strength Steel ◽  
Fluid Pressure ◽  
Cutting Speed ◽  
High Strength ◽  
Feed Speed ◽  
Machining Parameters ◽  
Deep Hole ◽  
Machining Quality ◽  
Gun Drill

Abstract There are a lot of problems exist in the processing of long and thin deep hole gun drilling of high strength steel, such as insufficient of the machining mechanism and characteristics of gun drilling, difficulty in selecting machining parameters, unknown influence mechanism of machining parameters on drilling force, drilling temperature and machining quality. In this paper, 42CrMo high strength steel is selected as the workpiece material. A numerical model of cutting force is established based on the mechanism of gun drill, and then the finite element simulation and processing test are carried out. The results show that the cutting force decreases with the increase of cutting speed, and increases with the increase of feed speed; the error between the theoretical and actual value is less than 10%. Cutting speed and feed speed have a great influence on machining quality, and the cutting fluid pressure mainly affects the surface roughness.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

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