Performance Study of Cryo-Treated End Mill Via Wet, Cryogenic, and Hybrid Lubri-Coolant-Milling Induced Surface Integrity of Biocompatible Mg Alloy AZ91D

2021 ◽  
pp. 095440622110171
Author(s):  
Rahul Davis ◽  
Abhishek Singh
Keyword(s):  
Surface Integrity ◽  
Sustainable Manufacturing ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Complete Healing ◽  
Mg Alloys ◽  
End Mill ◽  
Performance Study ◽  
High Cutting Speed ◽  
Coated Cemented Carbide

The excellent biodegradability of the magnesium (Mg) alloys is gradually proving them as the potential substitutes to several biomedical implants such as chemotherapy ports or screws, which are required to be removed via secondary surgeries after a specific period of time. However, an early degradation of these alloys even before the complete healing of the damaged tissue, when exposed to the physiological atmosphere, has been limiting their full-fledged application. Some latest research articles suggest that such challenges can be effectively overcome by improving the surface integrity of Mg alloys using the sustainable manufacturing techniques, such as cryogenic machining. Recent literatures also report the outperformance of the cryogenically treated (cryo-treated) cutting tools for achieving an enhanced surface integrity. In this relation, the present research attempts to improve the surface integrity of one of the most commonly used biocompatible alloys of magnesium, known as AZ91D. For this reason, a TiAlN coated-cemented carbide end mill was used in an untreated and cryo-treated state amid wet, cryogenic, and hybrid-lubri-coolant-milling conditions. The milling and FESEM (field emission scanning electron microscopy) results showed a considerable improvement in the surface integrity in terms of an augmented surface roughness and microhardness at 56.52 m/min cutting speed with the cryo-treated end mill during hybrid-lubri-coolant-milling. At the high cutting speed hybrid-lubri-coolant-milling, the cryo-treated end mill attained 35.71% and 48.07% better surface finish than that of cryo and wet-lubri-coolant-milling, respectively. Although, the highest surface microhardness was achieved by the cryo-treated end mill amid cryo-lubri-coolant-milling, due to the poorest surface quality observed in terms of the maximum number of machining-induced cracks, the hybrid-lubri-coolant-milled surface was preferred over the cryo and wet-lubri-coolant-milled surfaces. Further, the FESEM and EDS (energy-dispersive X-ray spectroscopy) analyses confirmed the oxide layer produced by the cryo-treated end mill amid hybrid-lubri-coolant-milling, to be the thinnest (12.16 µm) and most uniform passivation layer.

Cutting Performance and Wear Mechanism of Si3N4-Based Nanocomposite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 324-329 ◽  
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Jin Peng Song
Keyword(s):  
Wear Resistance ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Tool Materials ◽  
High Cutting Speed ◽  
The Matrix

Si3N4/TiN nanocomposite tool and Si3N4/Ti(C7N3) nanocomposite tool were prepared. The cutting performance and wear mechanism of Si3N4-based nanocomposite ceramic tool was investigated by comparison with a commercial sialon ceramic tool in machining of 45 steel. Si3N4-based nanocomposite ceramic tool exhibits the better wear resistance than sialon at the relatively high cutting speed. The increased cutting performance of Si3N4-based nanocomposite ceramic tool is ascribed to the higher mechanical properties. Nano-particles can refine the matrix grains and improve the bonding strength among the matrix grains of Si3N4-based nanocomposite ceramic tool materials. It contributes to an improved wear resistance of the cutting tools during machining.

Detecting the key geometrical features and grades of carbide inserts for the turning of nickel-based alloys concerning surface integrity

2016 ◽  
Vol 230 (20) ◽  
pp. 3725-3742 ◽  
Author(s):  
A Fernández-Valdivielso ◽  
LN López de Lacalle ◽  
G Urbikain ◽  
A Rodriguez
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Point Of View ◽  
Basic Operation ◽  
Workpiece Surface ◽  
Common Features ◽  
Feasible Solutions

Machining science is aimed at defining both cutting tools and machining conditions based on economic performance and to maintain workpiece surface integrity. Currently, machinists face a wide offer of turning, milling, drilling, and threading tools. Tools present a lot of similarities and light differences between them, being the latter the concealed reasons for a better or worse performance on difficult-to-cut alloys machining. However machinists had not useful methods for detecting which key tool aspects implies the best performance. The classic and expensive 'test-trial' method results non-viable due to the market exponential increase, both in size and specialization. This paper brings up an indirect method for seeking common features in the group of those tools with the best performance on machining Inconel 718. The method is divided into five stages, namely: (a) raw testing of a basic operation with a lot of commercial solutions for the same operation; (b) filtering of results to reduce the feasible solutions to a few ones, studying the common features of successful cases; (c) testing of these feasible solutions aimed at choosing the best insert or tool (d); and finally (e) full testing concerning all workpiece surface integrity issues. The proposed method provides knowledge based on the distilling of results, identifying carbide grades, chipbreakers shapes, and other features for having the best tool performance. All surface integrity effects are checked for the best solution. This new point of view is the only way for improving the difficult-to-cut alloys machining, reaching technical conclusions with industrial interest. This paper shows the method applied on Inconel 718 turning, resulting in a carbide grade with 10% cobalt, submicron grain size (0.5–0.8 µm) and hardness around 1760 HV, coating TiAlN monolayer with 3.5 µm thickness, chipbreaker giving 19° of rake angle that becomes 13° real one after insert is clamped on toolholder. Cutting edge radius after coating was 48 µm approximately. Cutting speed was 70 m/min higher in comparison with that recommended in handbooks.

Evaluation of Surface Integrity during Machining with Different Tool Grades of Sicp/Al-Si Composites Produced by Powder Metallurgy

2011 ◽  
Vol 672 ◽  
pp. 319-322 ◽  
Author(s):  
Mustafa Günay ◽  
Ulvi Şeker
Keyword(s):  
Surface Roughness ◽  
Powder Metallurgy ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machining Process ◽  
Machined Surface ◽  
Alloy Matrix ◽  
Surface Finishes

MMCs components are mostly produced using near net shape manufacturing methods and are subsequently machined to the final dimensions and surface finishes. The MMCs consist of extremely hard reinforcing particles and pose considerable challenges due to the poor machinability and severe wear of the cutting tool. In this study, cutting performance of WC, CBN and PCD cutting tools were investigated with respect to surface roughness during machining of 10 wt % SiCp reinforced Al-Si alloy matrix composites produced by powder metallurgy (PM) method. Average surface roughness (Ra) corresponding to each machining condition was measured. After the machining process the worn insert tips were examined under the scanning electron microscope (SEM). Chip geometry and machined surface photographs have been taken by optical microscopy. The experimental results showed that surface roughness decreased with increasing cutting speed for all of cutting tool materials. The best surface integrity was occurred after the machining with PCD insert at the highest cutting speed employed.

Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Sintered Steel

2015 ◽  
Vol 772 ◽  
pp. 72-76 ◽  
Author(s):  
Tadahiro Wada ◽  
Hiroyuki Hanyu
Keyword(s):  
Tool Wear ◽  
Cathode Material ◽  
Cutting Speed ◽  
Cemented Carbide ◽  
Coating Film ◽  
Sintered Steel ◽  
High Cutting Speed ◽  
Coated Tools ◽  
Coated Tool ◽  
Coated Cemented Carbide

In order to improve both the scratch strength and the micro-hardness of (Al,Cr)N coating film, the cathode material of an aluminum/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the aluminum/chromium target. In this study, hardened sintered steel was turned with (Al60,Cr25,W15)N, (Al60,Cr25,W15)(C,N), (Al64,Cr28,W8)(C,N), (Al,Cr)N and (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tool was experimentally investigated. The following results were obtained: (1) In cutting hardened sintered steel at the cutting speed of 0.42 m/s using the (Al60,Cr25,W15)N, the (Al60,Cr25,W15)(C,N), the (Al64,Cr28,W8)(C,N), the (Ti,Al)N and (Al,Cr)N coated tools, the wear progress of the (Al64,Cr28,W8)(C,N) coated tool became slowest among that of the five coated tools. (2) The wear progress of the (Al60,Cr25,W15)(C,N) coated tool was almost equivalent to that of the (Al64,Cr28,W8)(C,N) coated tool. However, at a high cutting speed of 1.67 m/s, the wear progress of the (Al60,Cr25,W16)(C,N) coated tool was faster than that of the (Al64,Cr28,W8)(C,N) coated tool.

Cutting Performance of Coated Cemented Carbide Tool in Driven Rotary Cutting of Hardened Steel

2019 ◽  
Vol 13 (1) ◽  
pp. 49-57 ◽  
Author(s):  
Hideharu Kato ◽  
Noriyuki Takase ◽  
Kentaro Watanabe ◽  
Tatsuya Shikimura ◽  
Kazuyuki Kubota ◽  
...  
Keyword(s):  
Oxidation Resistance ◽  
High Speed ◽  
High Efficiency ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Processing Efficiency ◽  
High Cutting Speed ◽  
Rotary Cutting ◽  
Coated Cemented Carbide

Recently, cutting has replaced grinding in the finishing process for hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high-feed rate conditions rather than more conventional cutting conditions. Therefore, a new cutting technique that can realize high-efficiency cutting is desired. In our previous study, the processing efficiency was improved three to five times compared with conventional hardened steel cutting by driven rotary cutting. Furthermore, to attain high efficiency, the resistance of the tool material to wear and oxidation must be improved. In this study, the cutting performance of tools with an Al-rich coating, which improves oxidation resistance, is investigated for high cutting speed applications. In the present experiments, the flank wear of the Al-rich tool was less than 40 μm at a high cutting speed of 2.51 m/s, even for a cutting length of 10.0 km. Additionally, the Al-rich tool wear advanced progressively without flaking. In contrast, the conventional TiAlN-coated tools exhibited serious failure at cutting lengths of 3.0 km. It is thought that the difference in the oxidation resistance of the two tools influenced the cutting performance. Therefore, the tool with the Al-rich coating can operate with a high efficiency even at high cutting speeds.

scholarly journals The Issues of Cryojet Technology Application for Rock Cutting

2018 ◽  
Vol 41 ◽  
pp. 03010
Author(s):  
Konstantin Golovin ◽  
Roman Kovalev ◽  
Andrey Kopylov
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Point Of View ◽  
Factors Affecting ◽  
Technology Application ◽  
High Cutting Speed ◽  
Main Factors

Water-jet technologies, based on the use of high-speed jets as cutting tools, are one of the promising directions of the destruction technologies for various materials. Jets’ capability to cut even very strong, anisotropic and composite materials, as well as their high cutting speed, that can be reached without workpiece reaction occurring on the tool, make them attractive from the point of view of their implementation as cutting tools. This paper outlines the methods of materials destruction by means of high-speed cryojet and discusses future areas of its application. The research reveals the main factors and criteria for evaluating the effectiveness of cryojet cutting. Experimental studies of the main factors affecting the cryojet cutting parameters were carried out using a bench unit. As a result of the experimental data analysis, we found the correspondences that can be used for calculating the cryojet cutting of various materials.

Tool wear and surface integrity of inconel 718 in dry and cryogenic coolant at high cutting speed

Wear ◽  
2017 ◽  
Vol 376-377 ◽  
pp. 125-133 ◽  
Author(s):  
A.H. Musfirah ◽  
J.A. Ghani ◽  
C.H. Che Haron
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Cutting Speed ◽  
High Cutting Speed

A Model-Based Prediction Approach to Understanding Tool Wear

2001 ◽  
Author(s):  
W. Kim ◽  
T. Wong ◽  
P. Kwon
Keyword(s):  
Phase Transformation ◽  
Tool Wear ◽  
Empirical Equation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Model Based ◽  
High Cutting Speed ◽  
Prediction Approach ◽  
Empirical Approaches

Abstract Since the development of Taylor’s wear equation in the early 1900s, empirical approaches to tool wear have been extensively used by industries. However, as many types of work materials and cutting tools have emerged, developing the empirical equation for each combination of work material and cutting tool is too costly and time-consuming. In this paper, we present a promising new model-based approach, where the developed model can be directly extended to other work materials and cutting tools. However, when machining pearlitic steels at high cutting speed, phase transformation restricts the model’s applicability. With phase transformation, the associated flank wear does not follow the model’s predictions. Evidently, the abrasive action of cementite is suppressed as the cementite phase in pearlitic microstructure transforms into austenite. This paper summarizes and reevaluates our previous experimental results in order to develop a model-based approach to understanding and predicting tool wear.

Finite Element Analysis for Deformation of Toolholder/Spindle Interface System at High Rotation Speed

2004 ◽  
Vol 471-472 ◽  
pp. 649-653 ◽  
Author(s):  
D.L. Wang ◽  
T.H. Li ◽  
D.C. Kang
Keyword(s):  
Finite Element ◽  
Rotation Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
The Finite Element Method ◽  
Element Analysis ◽  
High Cutting Speed ◽  
Interface System ◽  
Machining System ◽  
High Rotation Speed

With a significant progress achieved both in new kind of cutting tools and in machine tool design at high cutting speed, one of the weakest parts in the machining system is the toolholder/spindle interface system. In this paper the displacement of the 7/24 tapered tool interface and the HSK tool interface at high rotation speed is analyzed by means of the finite element method. The effects of the centrifugal force on the characteristics of the joints are investigated.

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