Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 2: Effect of tool failure modes

2015 ◽  
Vol 231 (9) ◽  
pp. 1575-1586 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Machined Surface ◽  
Tool Failure ◽  
Geometric Ratio ◽  
Cutting Speeds

Variation in the geometric and surface features of segmented chips with an increase in the volume of material removed and tool wear has been investigated at cutting speeds of 150 and 220 m/min at which the cutting tools fail due to gradual flank wear and plastic deformation of the cutting edge, respectively. Among the investigated geometric variables of the segmented chips, slipping angle, undeformed surface length, segment spacing, degree of segmentation and chip width showed the different variation trends with an increase in the volume of material removed or flank wear width, and achieved different values when tool failed at different cutting speeds. However, the chip geometric ratio showed a similar variation trend with an increase in the volume of material removed and flank wear width, and achieved the similar value at the end of tool lives at cutting speeds of both 150 and 220 m/min regardless of the different tool failure modes. Plastic deformation of the tool cutting edge results in severe damage on the machined surface of the chip and significant compression deformation on the undeformed surface of the chip.

Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

2007 ◽  
Author(s):  
Niniza S. P. Dlamini ◽  
Iakovos Sigalas ◽  
Andreas Koursaris
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Crater Wear ◽  
Compacted Graphite ◽  
Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

Analysis of Tool Wear: Part II: Applications of Flank Wear Models

1970 ◽  
Vol 92 (1) ◽  
pp. 109-114 ◽  
Author(s):  
A. Bhattacharyya ◽  
A. Ghosh ◽  
Inyong Ham
Keyword(s):  
Tool Wear ◽  
Critical Points ◽  
Quantitative Assessment ◽  
Inflection Point ◽  
Flank Wear ◽  
Cemented Carbides ◽  
Temperature Sensitive ◽  
Tool Failure ◽  
Cutting Speeds ◽  
Asme Paper

For machining with cemented carbides and ceramics, a quantitative assessment of tool failure at the flank for establishing “limit criterion” is necessary. The arbitrarily chosen flank wear limit for all cutting speeds is not valid at higher cutting speeds because of the earlier appearance of the “inflection point” which is often taken as criterion of flank-failure. In this paper, proceeding from the basic physical model of flank wear described in Part I of the paper (ASME Paper No. 68—WA/Prod-5), tool-life relations in the form of Taylor’s equations have been theoretically developed, the parameters of which have been compared with, experimental results. Further, the critical points of inflexion where the flank-wear characteristic enters temperature sensitive region resulting in accelerated wear have been uniquely defined. The location of these critical points have also been verified experimentally.

Performance Evaluation of TiAlN-PVD Coated Inserts for Machining Ti-6Al-4V under Different Cooling Strategies

2013 ◽  
Vol 685 ◽  
pp. 68-75 ◽  
Author(s):  
Salman Pervaiz ◽  
Ibrahim Deiab ◽  
Basil Darras ◽  
Amir Rashid ◽  
Mihai Nicolescu
Keyword(s):  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Machined Surface ◽  
Cutting Inserts ◽  
Low Levels ◽  
Coated Carbide ◽  
Cutting Experiments ◽  
Cutting Speeds ◽  
Scanning Electron

Titanium alloys are labeled as difficult to materials because of their low machinability rating. This paper presents an experimental study of machining Ti-6Al-4V under turning operation. All machining tests were conducted under dry, mist and flood cooling approaches by using a TiAlN coated carbide cutting inserts. All cutting experiments were conducted using high and low levels of cutting speeds and feed rates. The study compared surface finish of machined surface and flank wear at cutting edge under dry, mist and flood cooling approaches. Scanning electron microscopy was utilized to investigate the flank wear at cutting edge under various cooling approaches and cutting conditions. Investigation revealed that TiAlN coated carbides performed comparatively better at higher cutting speed.

scholarly journals Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

2016 ◽  
Vol 2016 ◽  
pp. 1-10 ◽  
Author(s):  
Manikandakumar Shunmugavel ◽  
Ashwin Polishetty ◽  
Junior Nomani ◽  
Moshe Goldberg ◽  
Guy Littlefair
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Flank Wear ◽  
Research Work ◽  
Cutting Speed ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
All Speeds ◽  
Cutting Speeds

This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

scholarly journals Tool Wear and Surface Integrity Analysis of Machined Heat Treated Selective Laser Melted Ti-6Al-4V

3D Printing ◽  
2017 ◽  
pp. 228-240
Author(s):  
Manikandakumar Shunmugavel ◽  
Ashwin Polishetty ◽  
Moshe Goldberg ◽  
Rajkumar Prasad Singh ◽  
Guy Littlefair
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Cutting Tools ◽  
Optical Microscope ◽  
Machined Surface ◽  
Microstructural Alterations ◽  
Heat Treated ◽  
Integrity Analysis ◽  
Rapid Tool ◽  
Cutting Speeds

In this study, the tool wear and surface integrity during machining of wrought and Selective Laser Melted (SLM) titanium alloy (after heat treatment) are studied. Face turning trails were carried out on both the materials at different cutting speeds of 60,120 and 180 m/min. Cutting tools and machined specimens collected are characterized using scanning electron microscope, surface profiler and optical microscope to study the tool wear, machined surface quality and machining induced microstructural alterations. It was found that high cutting speeds lead to rapid tool wear during machining of SLM Ti-6Al-4V materials. Rapid tool wear observed at high cutting speeds in machining SLM Ti-6Al-4V resulted in damaging the surface integrity by 1) Deposition of chip/work material on the machined surface giving rise to higher surface roughness and 2) Increasing the depth of plastic deformation on the machined sub surface.

Combined effects of various materials on tool wear in drilling of Ti/CFRP stacks

2019 ◽  
Vol 234 (14) ◽  
pp. 2750-2759
Author(s):  
Qi Wang ◽  
Fuji Wang ◽  
Chong Zhang ◽  
Chen Chen
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Thrust Force ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Combined Effects ◽  
Wear Process ◽  
Drill Bits ◽  
Tool Performance ◽  
The Relationship

Ti/CFRP stacks present the key function in the aviation field due to their excellent properties. However, both titanium alloy and CFRP are hard-to-cut materials and their requirements on cutting tool performance are significantly different. When drilling Ti/CFRP stacks using a compromised tool, tool wear is affected by two materials, resulting in extremely low tool life. This paper investigates the wear process of chisel edge and main cutting edge of carbide step drill bits in the drilling of Ti/CFRP stacks, titanium alloys and CFRP, and the combined effects of various materials on the tool wear are revealed. Based on the wear analysis, it is found that tool wear is more affected by the carbon fiber/Ti-adhesion interaction which makes the rake face more susceptible to occur adhesive wear and slows down the flank wear, and severe rake wear and flank wear have a sharpening effect on cutting edge. It also reveals the relationship between thrust force and tool wear, and results indicate that the variation of thrust force is related to the flank wear and the Ti-adhesion attached to chisel edge, but not to the edge rounding. The conclusions reported in this paper can provide guidance for structural optimization of long-life stacks cutting tools.

scholarly journals Tool Wear and Surface Integrity Analysis of Machined Heat Treated Selective Laser Melted Ti-6Al-4V

2016 ◽  
Vol 3 (2) ◽  
pp. 50-63 ◽  
Author(s):  
Manikandakumar Shunmugavel ◽  
Ashwin Polishetty ◽  
Moshe Goldberg ◽  
Rajkumar Prasad Singh ◽  
Guy Littlefair
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Cutting Tools ◽  
Optical Microscope ◽  
Machined Surface ◽  
Microstructural Alterations ◽  
Heat Treated ◽  
Integrity Analysis ◽  
Rapid Tool ◽  
Cutting Speeds

In this study, the tool wear and surface integrity during machining of wrought and Selective Laser Melted (SLM) titanium alloy (after heat treatment) are studied. Face turning trails were carried out on both the materials at different cutting speeds of 60,120 and 180 m/min. Cutting tools and machined specimens collected are characterized using scanning electron microscope, surface profiler and optical microscope to study the tool wear, machined surface quality and machining induced microstructural alterations. It was found that high cutting speeds lead to rapid tool wear during machining of SLM Ti-6Al-4V materials. Rapid tool wear observed at high cutting speeds in machining SLM Ti-6Al-4V resulted in damaging the surface integrity by 1) Deposition of chip/work material on the machined surface giving rise to higher surface roughness and 2) Increasing the depth of plastic deformation on the machined sub surface.

scholarly journals Investigation of Tool Failure Modes and Machining Disturbances Using Monitoring Signals

2011 ◽  
Vol 423 ◽  
pp. 128-142 ◽  
Author(s):  
Andrei Popa ◽  
Gilles Dessein ◽  
Maher Baili ◽  
Vincent Dutilh
Keyword(s):  
Failure Modes ◽  
Flank Wear ◽  
Machined Surface ◽  
Tool Failure ◽  
Tool Condition ◽  
Aero Engine ◽  
Key Factor ◽  
Nickel Base ◽  
Wear Tool ◽  
Spindle Current

The ACCENT Project (FP7-AAT-2007-RTD-1) will allow the European Aero Engine manufacturers to improve their competitiveness by applying adaptive control techniques to the manufacturing of their components. For the critical rotating parts of aircraft engines, the surface integrity generated after machining is a key factor on the life cycle. In this context, one particular attention has to be carried out on tool condition. The aim of this paper is to define a monitoring approach able to detect the tool condition and machining disturbances. The main failure modes characterizing this particular Nickel base drilling and the apparition of embedded chips over the machined surface were identified. By experimental techniques, cartography of failure modes was performed. The results show that flank wear and notch are the main failure modes limiting the tool life. For some cutting conditions, the tool failure occurs after the first hole due to the important cutting forces. Some interesting combinations are made between the spindle current/accelerometers/ thrust force and flank wear, tool breakage and notch. Before these correlations, a detailed signal analysis was performed, considering different disturbing phenomena, such as chips evacuation problem. Finally, a “synopsis” for process monitoring is proposed, considering the analyzed phenomena.

scholarly journals Impact of Cutting Speed on Tool Life of Coated and Uncoated Cemented Carbide during Turning of S31700 Grade Stainless Steel

2020 ◽  
Vol 9 (5) ◽  
pp. 2022-2025
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Stainless Steels ◽  
Entire Range ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cemented Carbides ◽  
Depth Of Cut ◽  
Cutting Speeds

Here, we found and observed different results of experimental work in dry turning of S31700 grade stainless steels using coated and uncoated cemented carbides. The turning tests were conducted at three different cutting speeds (150and 200m/min) while feed rate and depth of cut were kept constant at 0.3 mm/rev and 1 mm, respectively. The cutting tools used were ISO P30 uncoated and TiN-TiCN-Al2O3 -ZrCN coated cemented carbides. We found the influences of cutting speed on the average flank wear. The worn parts of the cutting tools were also examined using optical microscopy and SEM. Here we concluded that cutting speed significantly affected the average flank wear. The multilayer effects superior resistance to tool wear compared to its uncoated counterpart in the entire range of cutting speeds during turning of S31700 stainless (AISI317) steel.

Failure analysis of ceramic tool in intermittent turning of hardened steel

2017 ◽  
Vol 232 (12) ◽  
pp. 2140-2153 ◽  
Author(s):  
Xiuying Ni ◽  
Jun Zhao ◽  
Fuzeng Wang ◽  
Feng Gong ◽  
Xin Zhong ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Failure Modes ◽  
Failure Mechanisms ◽  
Cutting Tools ◽  
Transient Temperature ◽  
Ceramic Tool ◽  
Tool Failure ◽  
Fracture Modes ◽  
Intermittent Turning ◽  
Cutting Speeds

The aim of this investigation is to identify the Al2O3-(W, Ti)C ceramic fracture modes and failure mechanisms under different cutting speeds and feed rates during intermittent turning of hardened 20CrMnTi steel. The failure surfaces of the cutting tools were examined by digital optical microscope and scanning electron microscope. The cutting forces and transient temperature in the intermittent turning process were measured during the entire life cycle. The experimental results showed that the cutting forces exhibited an increasing trend with the tool failure progression, which in turn accelerated the tool failure progression. The main failure modes of ceramic tools were wear and micro-chipping in the initial stage and final fractures, resulting from mechanical damage and thermal damage in intermittent turning processes. And the cutting temperature increased with the increase in cutting speed. The cutting speeds and feed rates were closely correlated with ceramic tool fracture modes and failure mechanisms. Furthermore, the combination of cutting parameters was divided into four regions with different fracture modes and failure mechanisms of cutting tools according to the fracture morphology of cutting tools. This partitioning analysis can provide a basis for the design and development of different ceramic cutting tools with the desired properties for different applications.

Sign in / Sign up

Export Citation Format

Share Document