scholarly journals Internally cooled tools and cutting temperature in contamination-free machining

2013 ◽  
Vol 228 (1) ◽  
pp. 135-145 ◽  
Author(s):  
Carlo Ferri ◽  
Timothy Minton ◽  
Saiful Bin Che Ghani ◽  
Kai Cheng
Keyword(s):  
Heat Generation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Rake Face ◽  
Metal Working ◽  
Chip Temperature ◽  
Internally Cooled ◽  
Cutting Zone ◽  
And Diffusion

Whilst machining heat is generated by the friction inherent into the sliding of the chip on the rake face of the insert, the temperature in the cutting zone of both the insert and the chip rises, facilitating adhesion and diffusion. These effects accelerate the insert wear, ultimately undermining the tool life. Therefore, a number of methods have been developed to control the heat generation. Most typically, metal working fluids are conveyed onto the rake face in the cutting zone, with negative implications on the contamination of the part. Many applications for instance in health care and optics are often hindered by this contamination. In this study, microfluidics structures internal to the insert were examined as a means of controlling the heat generation. Conventional and internally cooled tools were compared in dry turning of AA6082-T6 aluminium alloy in two 33 factorial experiments of different machining conditions. Statistical analyses supported the conclusion that the chip temperature depends only on the depth of cut but not on the feed rate or on the cutting speed. They also showed that the benefit of cooling the insert internally increases while increasing the depth of cut. Internally cooled tools can therefore be particularly advantageous in roughing operations.

Performance Investigation of Modified Turning Tool Holder for MQL Application

2013 ◽  
Vol 465-466 ◽  
pp. 1114-1118
Author(s):  
Erween Abdul Rahim ◽  
Z.H. Samsudin ◽  
Muhammad Arif Abdul Rahim ◽  
Zazuli Mohid
Keyword(s):  
Single Channel ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Tool Holder ◽  
Dual Channel ◽  
Minimal Quantity Lubrication ◽  
Cutting Zone

Some machining process requires coolant to reduce the cutting temperature and helps to flush away the chips from the cutting zone. However, conventional flood coolant possesses some issues towards workers and the environment, regarding health and waste management. The implementation of Minimal Quantity Lubrication (MQL) as an alternative technique seems to be promising although the effectiveness of this technique were influenced by several factor. In turning process for instance, the distance of nozzle to the cutting zone contributes to the variation of machining performance. This study is to compare the effect on cutting performance between two internal MQL nozzle designs. The cutting tool holder were modified to have two internal MQL oil channel. The oil channel design were tested and the performance was evaluated in terms of cutting speed and cutting temperature for different cutting speed, feed rate and depth of cut. The result shows that the single channel performs better in terms of cutting force while dual channel significantly improve the cutting temperature.

Investigation on turning of AISI 1040 steel with the application of nano-crystalline graphite powder as lubricant

2013 ◽  
Vol 228 (9) ◽  
pp. 1570-1580 ◽  
Author(s):  
S Srikiran ◽  
K Ramji ◽  
B Satyanarayana ◽  
SV Ramana
Keyword(s):  
Heat Generation ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Graphite Powder ◽  
Chemical Degradation ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Feed Force ◽  
Particulate Solid ◽  
Cutting Zone

The past few decades have witnessed significant advancements in turning processes, cutting tools and coolant/lubricant chemistry. These developments have enhanced the machining capabilities of hard materials when machining at higher cutting conditions. Turning, being characterized by the development of high temperatures at the cutting zone, is critical with respect to the tool life and surface finish apart from other machining results like the forces generated. This phenomenon of heat generation at the cutting zone plays a negative role during turning operations due to their peculiar characteristics such as poor thermal conductivity, high strength at elevated temperature, resistance to wear and chemical degradation. Cutting fluids and solid lubricants are generally used to overcome the problem of heat generation at the cutting zone. The use of cutting fluids in the conventional way may not effectively control the heat generated in turning operation. Moreover, cutting fluids are a major source of pollution. With the advancement in technology, nano-level particulate solid lubricants are being used nowadays in machining operations, especially grinding and turning. The present work deals with the investigation of using nano-level particulate graphite powder as a solid lubricant and various tests were conducted by machining AISI 1040 steel using tungsten carbide inserts. The experiments were conducted by taking into account the parameters like feed rate ranging from 0.05 mm/rev to 0.125 mm/rev, cutting speed ranging from 51 m/min to 192.6 m/min and depth of cut from 0.25 mm to 1 mm. Four levels of each parameter are considered for experimentation. The results indicate that with the decrease in the nano-sized graphite powder, there is an increase of cutting forces – feed force, cutting force and thrust force. The temperatures at the tool–chip interface also increases with the decrease in the lubricant size. It is found that the surface roughness of the workpiece after machining deteriorated due to the size of the lubricant particle.

Deformation Replication

1970 ◽  
Vol 28 ◽  
pp. 280-281
Author(s):  
J. Temple Black
Keyword(s):  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Rake Face ◽  
Orthogonal Machining ◽  
Aluminum Chips ◽  
Before And After ◽  
Materials Used ◽  
Glass Knife ◽  
Very High

Tool materials used in ultramicrotomy are glass, developed by Latta and Hartmann (1) and diamond, introduced by Fernandez-Moran (2). While diamonds produce more good sections per knife edge than glass, they are expensive; require careful mounting and handling; and are time consuming to clean before and after usage, purchase from vendors (3-6 months waiting time), and regrind. Glass offers an easily accessible, inexpensive material ($0.04 per knife) with very high compressive strength (3) that can be employed in microtomy of metals (4) as well as biological materials. When the orthogonal machining process is being studied, glass offers additional advantages. Sections of metal or plastic can be dried down on the rake face, coated with Au-Pd, and examined directly in the SEM with no additional handling (5). Figure 1 shows aluminum chips microtomed with a 75° glass knife at a cutting speed of 1 mm/sec with a depth of cut of 1000 Å lying on the rake face of the knife.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Identification of Optimum Heating Temperature in Thermal Assisted Turning of Stainless Steel Using Three Different Approaches

2013 ◽  
Vol 393 ◽  
pp. 194-199 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Noor Hawa B. Mohamad Rasdi ◽  
Khairus Syakirah B. Mahmud ◽  
Abdul Hakam B. Ibrahim ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Heating Temperature ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Work Piece ◽  
Optimum Temperature ◽  
Main Concept

Thermal or heat assisted machining is used to machine hard and difficult-to-machine materials such as Inconel and Titanium alloys. The main concept is that localized surface heating of the work-piece reduces the yield strength of the material significantly, making it amenable to plastic deformation and machining. Thus, heat assisted machining has been used for over a century. However, the heating technique and temperature are very much dependent on the type of working material. Therefore, a multitude of heating techniques has been applied over the years including Laser Assisted Machining (LAM) and Plasma Enhanced Machining (PEM) in the industry. But such processes are very expensive and have not been found in wide scale applications. The authors of the current research have therefore looked into the application of a simple Tungsten Inert Gas (TIG) welding setup to perform heat assisted turning of AISI 304 Stainless Steel. Such welding equipment is relatively cheap and available. Also, stainless steel is perennially used in the industry for high strength applications. Hence, it is very important to determine with optimal cutting temperature when applying a TIG setup for heat assisted machining of stainless steel. This paper describes three separate techniques for determining the optimum temperature. All three processes applied the same experimental setup but used different variables for evaluating the best temperature. The first process used vibration amplitude reduction with increment in temperature to identify the desired temperature. The second process used chip shrinkage coefficient to locate the same temperature. And finally, the third process investigated tool wear as a criterion for determining the optimum temperature. In all three cases the three primary cutting parameters: cutting speed, feed, and depth of cut, were varied in the same pattern. The results obtained from all three approaches showed that 450oC was undoubtedly the best temperature for heat assisted machining of stainless steel.

Surface integrity in laser-assisted machining of Ti6Al4V

2020 ◽  
pp. 095440622097825
Author(s):  
O Kalantari ◽  
MM Fallah ◽  
F Jafarian ◽  
SR Hamzeloo
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Laser Source ◽  
Depth Of Cut ◽  
Thermal Source ◽  
Laser Assisted Machining

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

An Approach on Fuzzy and Regression Modeling for Hard Milling Process

2015 ◽  
Vol 813-814 ◽  
pp. 498-504 ◽  
Author(s):  
A. Tamilarasan ◽  
D. Rajamani ◽  
A. Renugambal
Keyword(s):  
Manufacturing Systems ◽  
Metal Removal ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Milling Process ◽  
Regression Modeling ◽  
Average Error ◽  
Depth Of Cut ◽  
Hard Milling ◽  
Radial Depth

This paper proposes the prediction of cutting temperature, tool wear and metal removal rate using fuzzy and regression modeling techniques for the hard milling process. The feed per tooth, radial depth of cut, axial depth of cut and cutting speed were used as process state variables.The experiements were conducted using RSM based central composite rotatable design methodology. Regression and fuzzy modeling were used to evaluate the input – output relationship in the process. It is interesting to observe that the R2 and average error values for each response are very consistent with small variations were obtained.Also, the confirmation results show that very less relative error varitions. Thus, the developed fuzzy models directly integrated in manufacturing systems to reduce the more computational complexity in the process planning activities.

Modeling of Cutting Performances in Turning Process Using Multiple Regression Method

2017 ◽  
Vol 29 ◽  
pp. 54-69 ◽  
Author(s):  
Samya Dahbi ◽  
Latifa Ezzine ◽  
Haj El Moussami
Keyword(s):  
Multiple Regression ◽  
Regression Models ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Performance Criteria ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Turning Process ◽  
Average Percentage ◽  
Multiple Regression Models

This paper presents the modeling of cutting performances in turning of 2017A aluminium alloy at four turning parameters: cutting speed, feed rate, depth of cut, and tool nose radius. These performances include: surface roughness, cutting forces, cutting temperature, material removal rate, cutting power, and specific cutting pressure. The experimental data were collected by conducting turning experiments on a Computer Numerically Controlled lathe and by measuring the cutting performances with forces measuring chain, an infrared camera, and a roughness tester. The collected data were used to develop multiple regression models for the pre-cited cutting performances and investigate the effects of turning parameters and their interactions on responses. To evaluate the accuracy of the developed models, two performance criteria were used: Correlation Coefficient (R²) and Average Percentage Error (APE). It was clearly seen that the multiple regression models estimate the cutting performances with high accuracy: R²>94% and APE<7%. Therefore, this method is an effective tool for modeling the cutting performances in turning process.

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

Manufacturing Accuracy when Drilling Holes in Stainless Austenitic Steels DIN 1.4301

2013 ◽  
Vol 420 ◽  
pp. 250-253 ◽  
Author(s):  
Jozef Jurko
Keyword(s):  
Stainless Steels ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Austenitic Steels ◽  
Depth Of Cut ◽  
Surface Accuracy ◽  
Cutting Zone ◽  
Manufacturing Accuracy

This article presents the results of experiments that concerned on the surface accuracy by drilling of a Stainless steels 1.4301. This article presents conclusions of machinability tests on a Stainless steels 1.4301. The results of cutting zone evaluation under cutting conditions (cutting speed in interval vc=50-100 m/min, depth of cut ap=2.75 mm and feed f=0.01-0,8 mm per rev.).

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