Surface characteristics and machining performance of TiAlN-, TiN- and AlCrN-coated tungsten carbide drills

2018 ◽  
Vol 233 (4) ◽  
pp. 1075-1086 ◽  
Author(s):  
Chaiya Dumkum ◽  
Pakin Jaritngam ◽  
Viboon Tangwarodomnukun
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Thrust Force ◽  
Surface Characteristics ◽  
Average Error ◽  
Force Model ◽  
Machining Performance ◽  
Coating Materials ◽  
Drilling Performance

This article presents a comprehensive analysis of surface characteristics and drilling performance of uncoated and coated tungsten carbide drills. The single- and double-layer coatings of TiN, TiAlN and AlCrN were examined in terms of surface roughness, microhardness and crack resistance. In addition, drilling torque and thrust force were experimentally measured and compared to the developed models based on the drilling mechanics and drill geometries. Tool wear and hole surface roughness were also considered to assess the machining performance of different coated tools. The results revealed that all coated drills can offer better cut surface quality, 28% lower cutting loads and longer tool life than the uncoated drills. Although AlCrN was found to be the hardest coating material among the others, it caused large wear on the cutting edges and poor surface roughness of produced holes. The lowest torque and thrust force were achievable using TiN-coated drill, while the use of TiAlN coating resulted in the lowest surface roughness and smallest tool wear. Furthermore, the drilling torque and thrust force model developed in this study were found to correspond to the experimental measures with the average error of 8.4%. The findings of this work could facilitate the selection of coating materials to advance the machining performance.

Precision Cutting of Structured Ceramic Molds with Micro PCD Milling Tool

2011 ◽  
Vol 5 (3) ◽  
pp. 277-282 ◽  
Author(s):  
Hirofumi Suzuki ◽  
◽  
Tatsuya Furuki ◽  
Mutsumi Okada ◽  
Katsuji Fujii ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Polycrystalline Diamond ◽  
Micro Milling ◽  
Grinding Wheels ◽  
Form Accuracy ◽  
Structured Surfaces ◽  
Milling Tool ◽  
Milling Tools

Micro milling tools made of PolyCrystalline Diamond (PCD) have been developed to machine ceramic micro dies and molds. Cutting edges are ground with diamond wheels. PCD milling tool wear is evaluated by cutting binder-less tungsten carbide spherical molds and machining structured surfaces for trial. Results of experiments clarified that PCD milling tool life is over 10 times that of resinoid diamond grinding wheels, and that form accuracy was 0.1 µm-0.3 µm P-V and surface roughness was 10 nm Rz.

Machining of a Rock Surface Shaver with a Piezoelectric Actuator forIn situAnalysis in Lunar and Planetary Exploration

2016 ◽  
Vol 10 (4) ◽  
pp. 533-539 ◽  
Author(s):  
Katsushi Furutani ◽  
◽  
Eiji Kagami ◽  
Keyword(s):  
Surface Roughness ◽  
Piezoelectric Actuator ◽  
Thrust Force ◽  
Sample Surface ◽  
Rock Surface ◽  
Composition Analysis ◽  
Machining Performance ◽  
Asteroid Exploration ◽  
Offset Voltage

Future lunar, planetary, and asteroid exploration will strongly demandin situanalysis of rock samples to obtain data related to various aspects. For precise composition analysis, a sample surface should be smoothed. In this paper, a surface shaver with a piezoelectric actuator is proposed and its machining performance in air is investigated. Shaving teeth are mounted at the ends of a pair of lever mechanisms. The device is pressed through four springs onto the workpiece with a linear actuator. When a sinusoidal voltage of 50 Vp-pand an offset voltage of 25 V were applied, the resonance frequency was 556 Hz and the unloaded amplitude of the shaving teeth was 0.77 mmp-p. Basalt workpieces were machined for 10 min in air. Increasing the thrust force reduced the surface roughness, although the amount removed diminished with a further increase in the thrust force. The surface roughness varied widely not only due to the amount removed but also due to containing the pores.

A Study on Machinability Performance of Silicon Carbide Paticulate Reinforced Metal Matrix Composite

2015 ◽  
Vol 766-767 ◽  
pp. 229-233
Author(s):  
R. Ganesh ◽  
R. Satyaprakash ◽  
M. Prakash ◽  
Chandrasekaran Kesavan
Keyword(s):  
Heat Treatment ◽  
Surface Roughness ◽  
Performance Indicators ◽  
Metal Matrix ◽  
Sintering Temperature ◽  
Weight Fraction ◽  
Machining Performance ◽  
Drilling Performance ◽  
Powder Metallurgy Route ◽  
Precipitation Heat

This paper aims to understand the influence of sintering temperature on the drilling performance of Al 2219 – SiCp composite. This type of composite is currently used in aerospace and transportation industries. Drilling is the most frequently employed operation of secondary machining owing to the need for fabrication. This composite is usually subjected to precipitation heat treatment and needs the study of influence of sintering temperature on machining performance. The composite is fabricated through powder metallurgy route. The drilling tests are conducted with PCD drill of 5 mm diameter and 118° point angle. The experiments are conducted under conditions of different spindle speeds of 500, 1000 and 1500 rpm and feed rates of 10, 15 and 20 mm/min. Specific cutting pressure and surface roughness of the hole are considered as performance indicators during the study. Weight fraction of the reinforcement and sintering temperature are found to have significant influence on the drilling performance of the composites.

A Comparative Study of Carbide Tools in Drilling of CFRP and CFRP-Ti Stacks

2011 ◽  
Author(s):  
Aaron Beal ◽  
Dave Dae-Wook Kim ◽  
Kyung-Hee Park ◽  
Patrick Kwon
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Comparative Study ◽  
Tungsten Carbide ◽  
Laser Scanning ◽  
Optical Microscope ◽  
Measuring System ◽  
Confocal Laser ◽  
Measuring Device ◽  
Twist Drills

A comparative study was conducted to investigate drilling of a titanium (Ti) plate stacked on a carbon fiber reinforced plastic panel. The effects on tool wear and hole quality in drilling using micrograin tungsten carbide (WC) tools were analyzed. The experiments were designed to first drill CFRP alone to create 20 holes. Then CFRP-Ti stacks were drilled for the next 20 holes with the same drill bit. This process was repeated until drill failure. The drilling was done with tungsten carbide (WC) twist drills at two different speeds (high and low). The feed rate was kept the same for each test, but differs for each material drilled. A Scanning Electron Microscope (SEM), and a Confocal Laser Scanning Microscope (CLSM), were used for tool wear analysis. Hole size and profile, surface roughness, and Ti burrs were analyzed using a coordinate measuring system, profilometer, and an optical microscope with a digital measuring device. The experimental results indicate that the Ti drilling accelerated WC flank wear while CFRP drilling deteriorated the cutting edge. Entry delamination, hole diameter errors, and surface roughness of the CFRP plate became more pronounced during drilling of CFRP-Ti stacks, when compared with the results from CFRP only drilling. Damage to CFRP holes during CFRP-Ti stack drilling may be caused by Ti chips, Ti adhesion on the tool outer edge, and increased instability as the drill bits wear.

scholarly journals An Investigation of the Effect of Parameters and Chip Slenderness Ratio on Drilling Process Quality of AISI 1050 Steel

2018 ◽  
Vol 2018 ◽  
pp. 1-9 ◽  
Author(s):  
Zülküf Demir ◽  
Rifat Yakut
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Thrust Force ◽  
Slenderness Ratio ◽  
Chip Morphology ◽  
Drilling Process ◽  
Steel Alloy ◽  
Drilling Operations ◽  
Machining Operations

The chip slenderness ratio is a vital parameter in theoretical and applicable machining operations. In predrilled drilling operations of AISI 1050 steel alloy, HSS drills were employed, and the effect of the selected parameters on the chip slenderness ratio and also the effect of the chip slenderness ratio on the thrust force, surface roughness, drilled hole delamination, tool wear, and chip morphology were investigated. The major parameters, influential on the chip slenderness ratio, were feed rate and point angle, while spindle speed was too small to be negligible. With increasing the chip slenderness ratio, the thrust force and the tool wear decreased, which resulted in appropriate chip morphology, but there were increases in surface roughness. However, the chip slenderness ratio had no effect on the drilled hole delamination.

scholarly journals Experimental Investigation On Machining Performance During Orbital Drilling of CFRP

2021 ◽  
Author(s):  
Linghao Kong ◽  
Dong Gao ◽  
Yong Lu ◽  
Pengfei Zhang
Keyword(s):  
Tool Wear ◽  
Thrust Force ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Machining Performance ◽  
Machining Quality ◽  
Orbital Drilling ◽  
Orthogonal Experiments ◽  
Hole Making ◽  
Tool Diameter

Abstract As the most promising CFRP hole making method, orbital drilling is widely concerned. This paper aims to understand the influence of the cutting parameters, tool diameters and ratio between milling and drilling (Rm&d) on thrust force, cutting temperature, tool wear and machining quality in CFRP orbital drilling. The effects of cutting parameters on thrust force and cutting temperature were studied by orthogonal experiments, and experiments were performed to investigate the variations of tool diameters, ratio between drilling and milling on thrust force, cutting temperature, tool wear and machining quality. The experimental results show that the tangential feed rate has no apparent effects on thrust force, but it appreciably impacts on the cutting temperature. The selection of tool diameter and the Rm&d has specific influence on tool wear, machining quality and cutting temperature. The result is helpful for selecting cutting parameters and tool diameters for high quality holes machining in CFRP orbital drilling.

scholarly journals ANALYSIS OF INFLUENCE OF CUTTING PARAMETERS ON SURFACE ROUGHNESS AND TOOL WEAR IN HARD TURNING SINTERED TUNGSTEN CARBIDE USING CBN INSERTS

2021 ◽  
Vol 226 (06) ◽  
pp. 18-24
Author(s):  
Nguyễn Quốc Tuấn ◽  
Ngô Minh Tuấn
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Hard Turning ◽  
Cutting Parameters ◽  
Sintered Tungsten ◽  
Chong Mai

Tiện cứng là một quá trình gia công có tiềm năng thay thế cho quá trình mài do có nhiều ưu điểm như năng suất cắt cao, bề mặt gia công tốt, thân thiện với môi trường. Cacbua vonfram thiêu kết được sử dụng rộng rãi để làm chày và khuôn cho các quá trình gia công biến dạng dẻo kim loại vì độ cứng cao và khả năng chống mài mòn so với thép hợp kim. CBN là vật liệu dụng cụ cắt siêu cứng được sử dụng để gia công các vật liệu khó gia công bằng cắt như cacbua vonfram. Trong nghiên cứu này, ảnh hưởng của các thông số cắt bao gồm vận tốc cắt, lượng chạy dao và chiều sâu cắt đến lượng mòn mặt sau và độ nhám bề mặt được phân tích bằng cách sử dụng mô hình thí nghiệm 2k với một số điểm thí nghiệm ở tâm. Kết quả nghiên cứu cho thấy lượng chạy dao là thông số có ý nghĩa nhất ảnh hưởng đến độ nhám bề mặt trong quá trình gia công và vận tốc cắt ảnh hưởng mạnh đến lượng mòn mặt sau của dao trong quá trình tiện cứng cacbua vonfram thiêu kết sử dụng mảnh CBN. Kết quả phân tích ANOVA đối với độ nhám bề mặt và lượng mòn mặt sau cho thấy cần phải sử dụng mô hình đường cong để mô tả ảnh hưởng của các thông số cắt đến độ nhám bề mặt và lượng mòn mặt sau trong quá trình gia công này.

Performance of Reground Tools in Drilling

2012 ◽  
Author(s):  
Jose Aecio Gomes de Sousa ◽  
Marcelo do Nascimento Sousa ◽  
Alisson Rocha Machado
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Thrust Force ◽  
Cemented Carbide ◽  
Machining Performance ◽  
Form Errors ◽  
First Time

The present work evaluates the performance of step drills, new and after regrinding. The tools were made of P20 cemented carbide coated with TiAlN. The routine of re-coating them after regrinding were varied (no recoating, recoating over the previous coating and recoating after removing the previous coating). The output parameters considered for determining the machining performance were: tool life, thrust force, torque, form errors (roundness and cylindricity) and surface roughness (Ra and Rz parameters). The results generated with the resharpened tools were compared to those obtained with a new tool (first time used). The results showed that in general the reground tools showed worse performance than the new tools, regardless the parameter considered. Only the tools that have undergone the process of cleanness of the previous coating and then reground and recoated (with the same type of coating) showed results similar to the new tools. The tools with no recoating and those that received the recoating over the previous showed, practically in all tests, higher thrust force and torque, larger form errors and worse surface roughness than the new tools.

Study on Effect of Ultrasonic Vibration in Machining of Alumina Ceramic

2012 ◽  
Vol 516 ◽  
pp. 311-316 ◽  
Author(s):  
Kyung Hee Park ◽  
Kyeong Tae Kim ◽  
Yun Hyuck Hong ◽  
Hon Jong Choi ◽  
Young Jae Choi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Ultrasonic Machining ◽  
Machining Performance ◽  
Machined Surface ◽  
Combination Technique

Ultrasonic machining can be applied for the machining of difficult-to-cut materials using ultrasonical oscillation in an axial direction on top of tool rotation, which can cause reduction of cutting temperature and tool wear. In this study, the experiments were performed on a DMG ULTRASONIC 20 linear machine tool using diamond tools in both conventional and ultrasonic vibration assisted machining. The machining performance was evaluated and compared for both cases in terms of cutting forces, machined surface roughness and tool wear. And the combination technique of 3D surface topography measurement and image processing was applied for the tool wear progress. Overall, the experimental results showed that ultrasonic machining had less tool wear and lower cutting forces at low cutting speed compared to conventional machining. Also surface roughness was slightly lower in ultrasonic machining than that without ultrasonic vibration.

Drilling of Carbon Fibre Composites: A Review

2014 ◽  
Vol 903 ◽  
pp. 3-8 ◽  
Author(s):  
Aishah Najiah Dahnel ◽  
Stuart Barnes ◽  
Pipat Bhudwannachai
Keyword(s):  
Tool Wear ◽  
Carbon Fibre ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Fibre Composite ◽  
Cutting Speed ◽  
Heterogeneous Structure ◽  
Drilling Performance ◽  
Carbon Fibre Composites

Machining of Carbon Fibre Composite (CFC), particularly drilling is frequently employed in many industries especially when dealing with joining, assembly and structural repair of the parts. This paper summarizes the properties of the CFC as well as the appropriate material and geometry of the cutting tool that should be used when drilling of the CFC in order to optimize the drilling performance. In addition, this work also presents the literature review on the relationship between cutting speed, feed rate, tool wear, thrust force and damage of the drilled CFC. The nature and heterogeneous structure of CFC often resulted in difficulty during their machining in terms of rapid tool wear and high thrust force. As a result, this always results in the damage of the drilled parts. Furthermore, higher cutting speed and lower feed rate are also recognized as significant factors which contribute to rapid wear of the cutting tool. Therefore, the use of tungsten carbide cutting tools, cutting fluids and cryogenic machining is seen to be a practical technique in optimizing the drilling performance involving CFC. In general, this work intends to provide a basic guideline and understanding regarding drilling of the CFC.

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