scholarly journals Tool Wear and Formation Mechanism of White Layer When Hard Milling H13 Steel under Different Cooling/Lubrication Conditions

2014 ◽  
Vol 6 ◽  
pp. 949308 ◽  
Author(s):  
Song Zhang ◽  
Jianfeng Li ◽  
Honggang Lv
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Formation Mechanism ◽  
White Layer ◽  
Minimum Quantity Lubrication ◽  
Cutting Condition ◽  
H13 Steel ◽  
Dry Cutting ◽  
Hard Milling ◽  
Cooling And Lubrication

The present work aims at revealing the formation mechanism of white layer and understanding the effects of tool wear and cooling/lubrication condition on white layer when hard milling H13 steel with coated cutting tools. Hard milling experiments were carried out, and tool wear and its effect on formation of white layer were investigated. Compared to dry cutting condition, CMQL (cryogenic minimum quantity lubrication) technique can obviously reduce tool wear and prolong tool life owing to its good cooling and lubrication properties. The optical images of the subsurface materials indicate that the formation of white layer is related to tool wear; moreover, the thickness of white layer increases with the increase of tool wear. SEM (scanning electron microscope) images and XRD (X-ray diffraction) analysis confirm that the formation of white layer is mainly due to the mechanical effect rather than the thermal effect. It also proves that white layer is partly decreased or can be totally eliminated by optimizing process parameters under CMQL cutting condition. CMQL technique has the potential to be used for achieving prolonged tool life and enhanced surface integrity.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Study on Tool Life and Tool Wear Mechanisms in Dry Cutting Pure Iron

2013 ◽  
Vol 770 ◽  
pp. 74-77 ◽  
Author(s):  
Jin Xing Kong ◽  
Liang Li ◽  
Dong Ming Xu ◽  
Ning He
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Pure Iron ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Condition ◽  
High Plasticity ◽  
Dry Cutting ◽  
Tool Wear Mechanisms

Pure iron is a kind of high plasticity and toughness material. In the process of cutting pure iron, the tool wear is very serious. In this paper, three kinds of cutting tools KC5010, K313 and 1105 are used in the cutting pure iron process and the tool wear tests in dry cutting condition with different cutting parameters have been carried out. According to the results, the tool wear mechanisms and tool life of three kinds of cutting tools have been compared and analyzed. It is concluded that the tool life of K313 is better than KC5010 and 1105 and the three kinds of tool mechanisms are primarily adhesion wear, diffusion wear and oxidation wear.

Influence of Minimum Quantity Lubrication on Cutting Force and Tool Wear during Machining of GH4169

2014 ◽  
Vol 893 ◽  
pp. 653-657 ◽  
Author(s):  
Ji Lie Zhou ◽  
Zhong Hao Sun ◽  
Yun Xian Wu ◽  
Yang Yu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Minimum Quantity Lubrication ◽  
Dry Cutting ◽  
Cooling Fluid ◽  
Wide Range ◽  
Minimal Quantity Lubrication ◽  
Minimal Quantity ◽  
Cooling And Lubrication ◽  
Cooling Methods

MQL system is introduced in this paper to verify the influences on the tool wear and cutting force that brought by MQL (minimal quantity lubrication) for high-temperature alloy. The system utilized various pressures that are caused by the compressed air flowing through the decrescent areas to absorb the liquid from the reservoir tank, and then the liquid was transported to the nozzle which could spray the liquid on the workpiece for cooling and lubrication. The results shown that MQL had an obvious advantage over dry cutting and traditional cooling methods; it could effectively reduce cutting forces and improve the tool life expectancy as well as processing quality and efficiency. The proposed method also had some other positive characteristics, such as the less dosage of cooling fluid and the environmental-friendly. It also can be applied to the processing of difficult-to-cut materials with a wide range of prospects.

Evaluation of Cooling Potential and Tool Life in Turning Using Metalworking Fluids Delivered in Supercritical Carbon Dioxide

2009 ◽  
Author(s):  
Andres F. Clarens ◽  
Ye-Eun Park ◽  
Jacob Temme ◽  
Kim Hayes ◽  
Fu Zhao ◽  
...  
Keyword(s):  
Carbon Dioxide ◽  
Tool Wear ◽  
Tool Life ◽  
Heat Removal ◽  
Minimum Quantity Lubrication ◽  
Metalworking Fluids ◽  
Compacted Graphite ◽  
Lower Viscosity ◽  
Cutting Zone ◽  
Machining Operations

Carbon Dioxide is an industrial byproduct that has been proposed as an alternative metalworking fluid (MWF) carrier with lower environmental impacts and better cooling potential than existing MWFs. This paper investigates the heat removal and tool life effects of rapidly expanding supercritical CO2 (scCO2)-based MWFs relative to MWFs delivered as a flood of semi-synthetic emulsion or as minimum quantity lubrication (MQL) sprays. When cutting both compacted graphite iron (CGI) and titanium, tool wear was most effectively controlled using the scCO2-based MWF compared with the other MWFs. Analysis in this paper suggests that the performance benefit imparted by rapidly expanding scCO2 appears to be related to both the cooling potential and penetration of the sprays into the cutting zone. High-pressure gas sprays have lower viscosity and higher velocity than conventional MWFs. An experiment in which the spray direction was varied clearly demonstrated the importance of spray penetration in tool wear suppression. The type of gas spray is also a significant factor in tool wear suppression. For instance, a spray of N2 delivered under similar conditions to CO2 effectively reduced tool wear relative to water based fluids, but not as much as CO2. This result is particularly relevant for MQL sprays which are shown to not cool nearly as effectively as scCO2 MWFs. These results inform development of scCO2-based MWFs in other machining operations, and provide insight into the optimization of scCO2 MWF delivery.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

scholarly journals Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771061 ◽  
Author(s):  
Duc Tran Minh ◽  
Long Tran The ◽  
Ngoc Tran Bao
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Minimum Quantity Lubrication ◽  
High Hardness ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Coated Carbide ◽  
Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

Basic Investigation of Tool Wear

1963 ◽  
Vol 85 (1) ◽  
pp. 33-37 ◽  
Author(s):  
H. Takeyama ◽  
R. Murata
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Condition ◽  
Rate Process ◽  
Mechanical Abrasion ◽  
Fundamental Investigation ◽  
First Approximation ◽  
Basic Investigation

This paper treats a fundamental investigation of tool wear and tool life mainly from the viewpoint of flank wear. The result reveals that the mechanism of tool wear in turning can be classified into two basic types: The mechanical abrasion which is directly proportional to the cutting distance and independent of the temperature; and the other is, so to speak, a physicochemical type which is considered to be a rate process closely associated with the temperature, of course. Although it depends upon the cutting condition which type of wear plays a more important role, the latter is predominant under usual conditions. According to the analyses and the experimental results, it has been found out that the tool life from the standpoint of flank wear can be predicted to a first approximation by the initial cutting temperature.

Experimental Study on Turning of Alloy Cast Iron with Coated and Uncoated Tools

2010 ◽  
Vol 135 ◽  
pp. 265-270 ◽  
Author(s):  
Q.C. Wang ◽  
Qing Long An ◽  
Ming Chen ◽  
Gang Liu ◽  
Yun Shan Zhang
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Tool Wear ◽  
Great Influence ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Tool ◽  
Coated Carbide ◽  
Alloy Cast Iron ◽  
Alloy Cast

Alloy cast iron cylinder is the mainstream product used in engine nowadays. However, the machinability of alloy cast iron is poor because of its enhanced mechanical properties. In this paper, turning experiment has been conducted to study machinability of alloy cast iron with uncoated and coated carbide tools under dry cutting condition. The results of the experiment indicated that the turning performance of alloy cast iron with coated tool was much better than uncoated tool in terms of cutting force coefficients and tool wear. Feed rate has a great influence on surface roughness, and appropriate tool wear is benefit of finished surface roughness.

Chaotic Tool Wear During Machining of Titanium Metal Matrix Composite (TiMMCs)

2014 ◽  
Author(s):  
Xuan-Truong Duong ◽  
Marek Balazinski ◽  
René Mayer
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Tool Life ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Titanium Metal

The initial tool wear during machining of titanium metal matrix composite (TiMMCs) is the result of several wear mechanisms: tool layer damage, friction - tribological wear, adhesion, diffusion and brace wear. This phenomenon occurs at the first instant and extends to only ten seconds at most. In this case the adhesive wear is the most important mechanism while the brace wear is considered as a resistance wear layer at the beginning of the steady wear period. In this paper, the effect of the initial tool wear and initial cutting conditions on tool wear progression and tool life is investigated. We proposed herein a new mathematical model based on the scatter wear and Lyapunov exponent to study quantitatively the “chaotic tool wear”. The Chaos theory, which has proved efficient in explaining how something changes in time, was used to demonstrate the dependence of the tool life on the initial cutting conditions and thus contribute to a better understanding of the influence of the initial cutting condition on the tool life. Based on the chaotic tool wear model, the scatter wear dimension and Lyapunov exponents were found to be positive in all case of the initial cutting conditions such as initial speed, feed rate and depth of cut. The initial cutting speed appears however to have the most significant impact on tool life. In particular, the mathematical model was successfully applied to the case of machining TiMMCs. It was clearly shown that changing the initial cutting speed by 20 m/min for the first two seconds of machining instead of keeping it constant at 60 m/min during the whole cutting process leads to an increase in the tool life (up to 24%).

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