scholarly journals Characterization of Tool Wear in High-Speed Milling of Hardened Powder Metallurgical Steels

2011 ◽  
Vol 2011 ◽  
pp. 1-13 ◽  
Author(s):  
Fritz Klocke ◽  
Kristian Arntz ◽  
Gustavo Francisco Cabral ◽  
Martin Stolorz ◽  
Marc Busch
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Thermal Characteristics ◽  
High Speed Steel ◽  
Vital Role ◽  
Cutting Performance ◽  
Cutting Length ◽  
Solid Carbide

In this experimental study, the cutting performance of ball-end mills in high-speed dry-hard milling of powder metallurgical steels was investigated. The cutting performance of the milling tools was mainly evaluated in terms of cutting length, tool wear, and cutting forces. Two different types of hardened steels were machined, the cold working steel HS 4-2-4 PM (K490 Microclean/66 HRC) and the high speed steel HS 6-5-3 PM (S790 Microclean/64 HRC). The milling tests were performed at effective cutting speeds of 225, 300, and 400 m/min with a four fluted solid carbide ball-end mill ( = 6, TiAlN coating). It was observed that by means of analytically optimised chipping parameters and increased cutting speed, the tool life can be drastically enhanced. Further, in machining the harder material HS 4-2-4 PM, the tool life is up to three times in regard to the less harder material HS 6-5-3 PM. Thus, it can be assumed that not only the hardness of the material to be machined plays a vital role for the high-speed dry-hard cutting performance, but also the microstructure and thermal characteristics of the investigated powder metallurgical steels in their hardened state.

Experimental Analysis of Wear Mechanism and Tool Life in Dry Drilling of Al2024

2012 ◽  
Vol 566 ◽  
pp. 217-221 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Raja Ishak Raja Hamzah ◽  
Abdolkarim Niazi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dry Machining ◽  
Hole Quality ◽  
High Cutting Speed

Aluminum alloy is widely used in industry and various researches has been done on machiability of this material mainly due to its low weight and other superior properties. Dry machining is still interesting topic to reduce the cost of manufacturing and environmental contaminations. In present study dry machining of Al 2024 investigated on tool life, tool wear mechanisms, hole quality, thrust force and torque. Different types of high speed steel (HSS) tools utilized at constant feed rate of 0.04 mm/rev and cutting speeds within the range of 28 and 94 m/min. Experimental results revealed that HSCo drills, performed better than HSS drills in terms of tool life and hole quality. The main wear mechanisms which analyzed by scanning electron microscope found abrasive and adhesion wear on flank face, besides, BUE observed at chisel and cutting edges. However tool wear and BUE formation found more significant at high cutting speed. In terms of thrust force, two facet HSCo tools, recorded higher thrust force than four facet HSS drills.

scholarly journals Threading Performance of Different Coatings for High Speed Steel Tapping

Coatings ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 464
Author(s):  
Alain Gil Del Val ◽  
Fernando Veiga ◽  
Octavio Pereira ◽  
Luis Norberto Lopez De Lacalle
Keyword(s):  
Tool Life ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Tialn Coating ◽  
Tool Performance ◽  
Thread Profile ◽  
Increase Tool Life

Threading holes using tapping tools is a widely used machining operation in the industry. This manufacturing process involves a great tool immersion in the part, which involves both friction and cutting. This makes the use of coatings critical to improving tool life. Four coatings are used based on Physical vapor deposition (PVD) technology—TiN, TiCN, TiAlN and TiAlN+WC/C are compared to uncoated tool performance. The effect of various coatings on the life of M12 × 1.5 tapping tools during threading of through holes 20 mm deep, in GG25 casting plates, dry and applying cutting speed of 50 m/min. The end-of-life criterion has been established based on a cutting torque of 16 N-m. Taking the uncoated tap as a basis for comparison, it is observed that coatings based on PVD technologies increase tool life doubling in the most advantageous case with the TiAlN coating. PVD type coatings provide better protection to wear at cylindrical area of the tool, where the thread profile is finished, than uncoated taps. The teeth located in the cone-cylinder transition zone of the taps suffer the most wear regardless of the coating. However, taps coated with TiAlN+WC/C wear level values is lowest of all the coatings tested, which indicates a strong reinforcement in these teeth.

Feasibility Study of the Effectiveness of Cryogenically Treated Ceramic Inserts for Pocket Milling Maneuvers

2009 ◽  
Author(s):  
Justin L. Milner ◽  
Jeffrey A. Beers ◽  
John T. Roth
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Feasibility Study ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Initial Study ◽  
Machining Processes ◽  
Cutting Speeds

Machining is a popular and versatile manufacturing process that is widely used in today’s industry when producing metallic parts; however, limited tool life can make this an expensive and time consuming fabrication technique. Consequently, methods that decrease the rate of tool wear and, thus, increase tool longevity are a vital component when improving the efficiency of machining processes. To this end, cryogenically treating cutting tools (especially high-speed steel tooling) is becoming more commonplace since research has shown that the treated tooling exhibits significantly higher wear resistance. At this point, however, the effect of cryogenic treatments on ceramic tooling has not been established. Considering this, the research herein presents a feasibility study on the effectiveness of using cryogenic treatments to enhance the wear resistance of WG-300 whisker-reinforced ceramic cutting inserts. To begin, the effect of the cryogenic treatment on the insert’s hardness is examined. Subsequently, tool wear tests are conducted at various cutting speeds. Through this study, it is shown that cryogenically treating the ceramic inserts decreases the rate of tool wear at each of the cutting speeds that were tested. However, the degree of wear resistance introduced by cryogenically treating the inserts proved to be highly dependent on the cutting speed, with slower speeds exhibiting greater improvements. Thus, based on this initial study, the cryogenic treatment of ceramic tooling appears to produce beneficial results, potentially increasing the overall efficiency of machining processes.

Experimental Study of Cutting Performance and Tool Wear in Dry Side Milling of Aluminum Alloy with DLC-Coated HSS-Co Cutter

2012 ◽  
Vol 523-524 ◽  
pp. 64-69
Author(s):  
Yoshio Mizugaki ◽  
Kazuki Takafuji ◽  
Koichi Kikkawa ◽  
Teppei Kuroda ◽  
Taro Kimura
Keyword(s):  
Aluminum Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Experimental Results ◽  
Steel Matrix ◽  
Milling Cutter ◽  
Side Milling ◽  
Radial Depth

This paper presents the experimental results of cutting performance and tool wear of a milling cutter in dry side milling of aluminum alloy A2017. The milling cutter consists of Co-bonded High-Speed-Steel matrix with Diamond-Like-Carbon coating (abbrev. DLC-coated HSS-Co cutter). The machining experiments were carried out under cutting speed of 63 to 189 [m•min-1] and feed of 0.08 [mm/tooth/rev], and the criterion of tool life was the generation of gauge and/or scratch on a machined surface. The experimental results support that the DLC-coated cutter in up cutting has good performance among four types of combination by the presence or absence of coating and the up/down cutting manner. They also showed that the tool life of DLC-coated cutter in up cutting under cutting speed of 157 [m•min-1] was corresponding to the cutting distance of 80 [m] with average width of flank wear 102 [μm] and that in down cutting was 60 [m] with 85 [μm]. In the range of cutting distance up to 100 [m], the resultant cutting force with the DLC-coated cutter was smaller than that with a non-coating cutter. In case of the DLC-coated cutter in up cutting under the cutting speed of 189 [m•min-1], a chatter vibration occurred during the initial cutting distance. In case of the radial depth of cut of 1.5 [mm], it lasted up to the cutting distance of 10 [m] and more.

Criticism of Radioactive Tool-Life Testing

1963 ◽  
Vol 85 (4) ◽  
pp. 381-385 ◽  
Author(s):  
N. H. Cook ◽  
A. B. Lang
Keyword(s):  
Tool Wear ◽  
Tungsten Carbide ◽  
Tool Life ◽  
High Speed ◽  
High Speed Steel ◽  
Cutting Conditions ◽  
Life Testing ◽  
Wear Tests ◽  
Lathe Tool

Tungsten carbide and high-speed-steel lathe tool wear tests, carried out by conventional means and by radioisotope techniques, are compared. When the irradiated tool is used to cut under only one set of conditions, good correlation is obtained between the two methods. When the irradiated tool is used under a variety of cutting conditions, correlation is poor. If a single tool is used under different cutting conditions, it is doubtful if differences of less than 2:1 are significant.

Tool-Life Optimization in High-Speed Milling of Aeronautical Aluminum Alloy 7050-T7451

2009 ◽  
Vol 626-627 ◽  
pp. 117-122
Author(s):  
Y.Z. Pan ◽  
Xing Ai ◽  
Jun Zhao ◽  
X.L. Fu
Keyword(s):  
Aluminum Alloy ◽  
Tool Life ◽  
High Speed ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Least Square ◽  
High Speed Milling ◽  
Solid Carbide ◽  
Multi Linear Regression

A new approach is presented to optimize the tool life of solid carbide end mill in high-speed milling of 7050-T7451 aeronautical aluminum alloy. In view of this, the multi-linear regression model for tool life has been developed in terms of cutting speed and feed per tooth by means of central composite design of experiment and least-square techniques. Variance analyses were applied to check the adequacy of the predictive model and the significances of the independent parameters. Response contours of tool life and metal removal rates were generated by using response surface methodology (RSM). The analysis results show that it is possible to select an optimum combination of cutting speed and feed per tooth that improves metal removal rate without any sacrifice in tool life.

Predictive Tool Life Model of CBN in Ti6Al4V High Speed Turning and Cutting Parameter Optimization

2009 ◽  
Vol 407-408 ◽  
pp. 594-598
Author(s):  
Xiao Qin Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Pei Quan Guo
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Efficiency ◽  
Predictive Tool ◽  
Cbn Tool ◽  
Small Depth ◽  
Cutting Parameter Optimization

Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with CBN (Cubic Boron Nitride) in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of CBN tool. Finally, the cutting parameters of CBN tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the higher cutting speed and small depth of cut are the better selection, it means that utilization of CBN tool enables the high cutting speed turning of Ti6Al4V.

Optimization of Parameter for HSS Tool Wear by Using Taguchi Method and Finite Element Method

2013 ◽  
Vol 315 ◽  
pp. 151-155
Author(s):  
M.R. Ibrahim ◽  
A.R. Abd. Kadir ◽  
M.S. Omar ◽  
S. Sulaiman ◽  
M.H. Osman
Keyword(s):  
Tool Wear ◽  
Taguchi Method ◽  
Surface Treatment ◽  
High Speed ◽  
Flank Wear ◽  
Simulation Analysis ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Coated Surface

This paper presents the combination between the simulation analysis of FEM (DFORM 3D) and Taguchi method approach. The Taguchi method was used to find the optimize parameter design contribute to Flank wear. The parameters were evaluated are coated surface treatment, cutting speed and feed rate. The Usuis model carried out to measure the flank wear size. Furthermore, ANOVA analysis was used out to identify the influence factors contribute to tool wear in the signal to noise ratio. The experiments were conducted on AL6061 by using High Speed Steel Tool (HSS) in face milling cutting. It shown that, the coated surface treatment is the most significant parameter which can reduce the tool wear value.

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.

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