scholarly journals Content Comparative Investigation on Tool Wear During End Milling of AISI H13 Steel with Different Tool Path Strategies

2017 ◽  
Vol 6 (4) ◽  
pp. 327-333
Author(s):  
Erry Yulian T. Adesta ◽  
Muhammad Riza ◽  
Avicenna Avicenna
Keyword(s):  
Tool Wear ◽  
Experimental Work ◽  
Tool Path ◽  
End Milling ◽  
Cutting Speed ◽  
Comparative Investigation ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
H13 Steel ◽  
Coated Carbide

Tool wear prediction plays a significant role in machining industry for proper planning and control machining parameters and optimization of cutting conditions. This paper aims to investigate the effect of tool path strategies that are contour-in and zigzag tool path strategies applied on tool wear during pocket milling process. The experiments were carried out on CNC vertical machining centre by involving PVD coated carbide inserts. Cutting speed, feed rate and depth of cut were set to vary. In an experiment with three factors at three levels, Response Surface Method (RSM) design of experiment with a standard called Central Composite Design (CCD) was employed. Results obtained indicate that tool wear increases significantly at higher range of feed per tooth compared to cutting speed and depth of cut. This result of this experimental work is then proven statistically by developing empirical model. The prediction model for the response variable of tool wear for contour-in strategy developed in this research shows a good agreement with experimental work.

Preheating in End Milling of AISI D2 Hardened Steel with Coated Carbide Inserts

2009 ◽  
Vol 83-86 ◽  
pp. 56-66 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
A.M.K. Hafiz
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Inductive Heating ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Coated Carbide

This study was conducted to investigate the effect of preheating through inductive heating mechanism in end milling of AISI D2 hardened steel (60-62 HRC) by using coated carbide tool inserts. Apart from preheating, two other machining parameters such as cutting speed and feed were varied while the depth of cut constant was kept constant. Tool wear phenomenon and machined surface finish were found to be significantly affected by preheating temperature and other two variables. End milling operation was performed on a Vertical Machining Centre (VMC). Preheating of the work material to a higher temperature range resulted in a noticeable reduction in tool wear rate leading to a longer tool life. In addition, improved surface finish was obtained with surface roughness values lower than 0.4 μm, leaving a possibility of skipping the grinding and polishing operations for certain applications.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Cutting Temperature Behaviours in End Milling of Pocket by Applying Contour-In Tool Path Strategy

2015 ◽  
Vol 1115 ◽  
pp. 47-50 ◽  
Author(s):  
Muhammad Riza ◽  
Erry Yulian Triblas Adesta ◽  
M. Yuhan Suprianto
Keyword(s):  
High Speed ◽  
Tool Path ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Milling Process ◽  
Depth Of Cut ◽  
Path Direction ◽  
Major Factors ◽  
Coated Carbide

Cutting temperature generated during high speed machining operations has been recognized as major factors influence tool performance and workpiece geometry. This paper aims to model the cutting temperature and to investigate cutting temperature behaviours when contour-in tool path strategy applied in high speed end milling process. The experiments were carried out on CNC vertical machining center by involving PVD coated carbide inserts. Cutting speed, feed rate and depth of cut were set to vary. Results obtained indicate that cutting temperature is high in the initial stage of milling and at the corners region or turning points region. Portion of radial width of cut with workpiece in combination with the abrupt change of the milling path direction occur particularly in acute internal corners of a pocket leads to rise of cutting temperature.

Multiobjective Optimization of End Milling HCHCr Using AlCrN PVD Coated Cutters With MOGA and RSMO

2014 ◽  
Author(s):  
Shantisagar K. Biradar ◽  
Geeta S. Lathkar
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Multiobjective Optimization ◽  
End Milling ◽  
Dominant Role ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Machining Parameters

Here the End milling is studied for optimization of responses such as surface roughness and tool wear while machining HCHCr. These two conflicting responses decide the quality of process; therefore the multiobjective optimization technique is used. The Response Surface Optimizer (RSMO) and Multiobjective Genetic Algorithm (MOGA) were used as the multiobjective optimization techniques. The PVD coating of 2.5 micron AlCrN was used on four flute HSS End milling cutter. Input machining parameters were cutting speed, feed rate, depth of cut and percentage concentration of the solid lubricant MoS2 mixed with SAE-20 base oil. The experimentation was carried out using two level full factorial design concept while ANOVA technique has been used to verify the adequacy of mathematical model. It was found that the cutting speed (V) is having most dominant role on surface roughness and tool wear. The sensitivity analysis was carried out for studying sensitivity of input parameters for the responses.

Investigation on Wear Behavior and Chip Formation During Up-Milling and Down-Milling Operations for Inconel 718

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
M. A. Hadi ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Inconel 718 ◽  
End Milling ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Milling Operations ◽  
Milling Operation ◽  
Coated Carbide

A comprehensive study and FEM simulation of ball nose end milling on tool wear behavior and chip formation had been performed on Inconel 718 (nickle-based superalloy) under minimum quantity lubricant (MQL) condition. In this paper, the investigation was focusing on the comparison of up-milling and down-milling operations using a multi-layer TiAlN/AlCrN-coated carbide inserts. A various cutting parameters; depth of cut, feed rate and cutting speed were considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear compared to up-milling operation. Chipping on cutting tool edge responsible to notch wear with prolong machining. It was observed that the chips formed in up-milling operation were segmented and continuous, meanwhile down-milling operation produced discontinuous type of chips.

Experimental Investigation on Tool Wear when End-Milling Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 410-415 ◽  
Author(s):  
Yuan Wei Wang ◽  
Jian Feng Li ◽  
Z.M. Li ◽  
Tong Chao Ding ◽  
Song Zhang
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Coated Carbide ◽  
Carbide Inserts

In this paper, some experiments were conducted to investigate tool wear when end-milling Inconel 718 with the TiAlN-TiN PVD coated carbide inserts. The worn tools were examined thoroughly under scanning electron microscope (SEM) with Energy Dispersive X-ray Spectroscopy and 3D digital microscope to expatiate tool wear morphologies and relevant mechanisms. The flank wear was uniformity in finishing milling process, and the average flank wear were selected as the criterion to study the effects of cutting parameters (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) on tool wear. Finally, the optimal combination of the cutting parameters for the desired tool life is obtained.

An Experimental Study of Cutting Forces in Ball-End Milling of AISI H13

2013 ◽  
Vol 690-693 ◽  
pp. 2403-2407
Author(s):  
Tong Chao Ding
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
H13 Steel ◽  
Hard Milling ◽  
Radial Depth ◽  
Aisi H13 ◽  
Coated Carbide

In the present study, an attempt has been made to experimentally investigate the effects of the cutting parameters on cutting forces in hard milling of AISI H13 steel with coated carbide tools. Designed based on Taguchi method, four factor (cutting speed, feed, radial depth of cut and axial depth of cut) four level orthogonal experiments were conducted. Three components of cutting forces were measured during hard milling experiments and then variance analysis was performed. Finally, the linear regression model was established.

Tool Wear Analysis in End Milling of Advanced Ceramics with TiAlN and TiN Coated Carbide Inserts

2012 ◽  
Vol 576 ◽  
pp. 76-79
Author(s):  
M. Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein ◽  
D. Sujan ◽  
Mohammad Yeakub Ali ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
High Hardness ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Carbide ◽  
Axial Depth

Advanced ceramic materials are difficult to machine by conventional methods due to the brittle nature and high hardness. The appropriate selection of cutting tool and cutting conditions may help to improve machinability by endmilling. Performance of TiAlN and TiN coated carbide tool insert in end milling of machinable glass ceramic has been investigated. Several dry cutting tests were performed to select the optimum cutting parameters for the endmilling in order to obtain better tool life. In this work, a study was carried out on the influence of cutting speed, feed rate and axial depth of cut on tool wear.The technique of design of experiments (DOE) was used for the planning and analysis of the experiments. Tool wear prediction model was developed using Response surface methodology.The results indicate that tool wear increased with increasing the cutting speed and axial depth of cut. Effect of feed rate is not much significant on selected range of cutting condition

Multi-Criteria Optimization in End Milling of AISI D2 Hardened Steel Using Coated Carbide Inserts

2011 ◽  
Vol 264-265 ◽  
pp. 907-912
Author(s):  
A.N. Mustafizul Karim ◽  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Machining Operations ◽  
Coated Carbide ◽  
Desirability Index

This paper proposes a multi-criteria optimization technique using the mathematical models developed by the response surface methodology (RSM) for the target responses combined with desirability indices for the determining the optimum cutting parameters in end milling of AISI D2 hardened steels. Different responses may require different targets either being maximized or minimized. Simultaneous achievement of the optimized (maximum or minimum) values of all the responses is very unlikely. In machining operations tool life and volume metal removed are targeted to be maximized whereas the machined surface roughness need to be at minimum level. Models showing the combined effect of the three control factors such as cutting speed, feed, and depth of cut are developed. However, a particular combination of parameter levels appears to be optimum for a particular response but not for all. Thus adoption of the method of consecutive searches with higher desirability values is found to be appropriate. In this study the desirability index reaches to a maximum value of 0.889 after five consecutive solution searching. At this stage, the optimum values of machining parameters - cutting speed, depth of cut and feed were determined as 44.27 m/min, 0.61 mm, 0.065 mm/tooth respectively. Under this set condition of machining operations a surface roughness of 0.348 μm and volume material removal of 7.45 cm3 were the best results compared to the rest four set conditions. However, the tool life would be required to compromise slightly from the optimum value.

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