Surface morphology and microstructural analysis of al 8081-mg/zr/tio2 nano metal matrix composite – A base for performance evaluation of polycrystalline diamond and poly cubic boron nitride tools

2021 ◽  
pp. 095440622110591
Author(s):  
Balla S Prasad ◽  
Chandra M KarakaVVNR ◽  
Venkata S Annavarapu
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Surface Morphology ◽  
Metal Matrix ◽  
End Milling ◽  
Cubic Boron Nitride ◽  
Microstructural Analysis ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Tool Performance

The investigation of surface roughness in machined materials/products has proven to be a difficult undertaking. The surface quality is determined not only by the parameters but also by the cutting conditions. Surprisingly, a study indicated that when analysing the quality of machining processes currently being done, surface morphology has a significant impact on tool performance. PCD (Polycrystalline diamond) and PCBN (Poly cubic boron nitride) cutting tools produce a better surface finish, which is explored in the machining of Al-Mg/Zr/TiO2 (15%), nano metal matrix composites (NMMC). The study primarily focuses on determining the best parameters for end milling NMMCs in tests for long-term production sustainability. Using scanning electron microscopy, microstructural study of the machined surface will aid in finding the parameters responsible for the cause of surface integrity. The work focusses on analysing tool performance by monitoring the machining process in real time using signal characteristics, forecasting vibrations (displacement) and machine outputs using surface topography and chip analysis. The tool failure was acquired by establishing a correlation between displacement (vibrations) and post machining outcome of experimental study, as a result, the evolution of displacement in the PCBN tool is 24.7 μm, which is better compared to 34.3 μm in the PCD tool at 3000 r/min. PCBN outperformed PCD with a 1.82 μm surface roughness, resulting in longer tool life. Thus, this economical reliable empirical method the problem of finding difficulty identifying the causing of tool wear and failure by correlating sensor signals features with experimental results.

Effectiveness of Hard Turning

2013 ◽  
Vol 801 ◽  
pp. 109-116
Author(s):  
Michal Adamik ◽  
Róbert Drlička ◽  
Milan Matúš ◽  
Ján Žitňanský
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Hard Turning ◽  
New Technology ◽  
Cubic Boron Nitride ◽  
Polycrystalline Diamond ◽  
Cutting Edge ◽  
Hard Part ◽  
Machined Parts

Hard turning is a turning operation performed on hard materials (hardness more than 45 HRC) in order to reach surface roughness close to that obtained in grinding. The development of this technology was accompanied by the development of new cutting materials such as cutting ceramics, cubic boron nitride and polycrystalline diamond. Especially cubic boron nitride has found its use in hard part turning operations because of its characteristics. However, new cutting materials result in new questions, which researchers are trying to solve. The major consideration for a user of this relatively new technology is the quality of parts produced and how the new cutting material will behave during machining. This paper aims to document and describe the process of wear on the cutting edge of a tool made from cubic boron nitride of a different grade and with a different geometry of the cutting edge, and its influence on surface roughness and quality. Wear was documented by a digital microscope with measurement option. Surface roughness was measured by a roughness meter. A notable observation from this research is that the flank wear of the cutting tool has a large impact on the quality of machined parts (especially surface finish and surface integrity) [1].

scholarly journals Investigation of Optimum Grinding Condition Using cBN Electroplated End-Mill for CFRP Machining

2021 ◽  
Vol 15 (1) ◽  
pp. 4-16
Author(s):  
Shinnosuke Yamashita ◽  
Tatsuya Furuki ◽  
Hiroyuki Kousaka ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Airline Industry ◽  
End Milling ◽  
Cubic Boron Nitride ◽  
Machining Process ◽  
End Mill ◽  
Machined Surface ◽  
Side Milling ◽  
Reinforced Plastics ◽  
Grinding Tool

Recently, carbon fiber reinforced plastics (CFRP) have been used in various applications such as airplanes and automobiles. In CFRP molding, there are unnecessary portions on the outer area. Therefore, a machining process is required to remove them. Cutting and grinding are conventionally used in the finish machining of CFRPs. End-milling allows the removal of most of these portions. However, uncut fibers easily occur during end-milling. In contrast, a precise machined surface and edge are easily obtained using a grinding tool. Therefore, this research has developed a novel cubic boron nitride (cBN) electroplated end-mill that combines an end-mill and a grinding tool. This is a versatile tool that can cut and grind CFRPs by changing the direction of rotation of the tool. In this study, the effectiveness of the developed tool is investigated. First, the developed tool machined the CFRP by side milling. Consequently, cBN abrasives that were fixed on the outer surface of the developed tool did not detach in certain cutting conditions. Next, in order to generate a sharp edge on the CFRP and restrict the increase in the CFRP temperature with the cBN electroplated end-mill, the optimum abrasive size and grinding condition were investigated through the design of experiments. Moreover, the effectiveness of the developed tool was verified by comparing it with a conventional tool. As a result, smaller burrs and uncut fibers were observed after final machining with the developed tool under the derived optimum condition than those with conventional tools. However, the desired surface roughness could not be achieved as required by the airline industry. Therefore, oscillating grinding was applied. In addition, the formula of the theoretical surface roughness while using the developed tool was derived using the theory of slant grinding. As a result, the oscillating condition that led to the required surface roughness was obtained by theoretical analysis. In addition, the required value for the airline industry was achieved by oscillating grinding.

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

Development of Super-Hard Cutter Material

2013 ◽  
Vol 341-342 ◽  
pp. 3-7
Author(s):  
Hui Ying Feng ◽  
Xiao Jing Li
Keyword(s):  
High Speed ◽  
Cubic Boron Nitride ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Main Research ◽  
High Speed Cutting ◽  
Finished Surface ◽  
Materials Used ◽  
Surface Precision

Super-hard tool material is a main research point of mechanical engineering because of excellent performance. The development of technology for high-speed cutting process could enhance the machining quality and surface precision. It is a difficulty thing to get higher finished surface for traditional machining process. However, the super-hard cutter material could enhance the finished performance of tool material. For example, the wearing resistance, high stability of PCD (polycrystalline diamond) and PCBN (poly cubic boron nitride) can get more information for obtaining higher finished surface quality. The author introduces super-hard cutters materials (PCD and PCBN) development, and discusses several material properties. The features of materials used in different cutting fields are discussed.

PREDICTION AND INVESTIGATION OF SURFACE ROUGHNESS WHILE TURNING SG IRON WITH CUBIC BORON NITRIDE (CBN) AND TUNGSTEN CARBIDE INSERTS

2017 ◽  
Vol 41 (1) ◽  
pp. 129-141 ◽  
Author(s):  
K.M. Kumar ◽  
P. Hariharan
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tungsten Carbide ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Spheroidal Graphite ◽  
Surface Model ◽  
Sg Iron ◽  
The Impact

This work compares the effect of cubic boron nitride (CBN) and multilayer (TiCN+Al2O3+TiN) coated tungsten carbide (WC) tools during the turning of spheroidal graphite (SG) nodular iron. Nodular irons have more ductility which is required in mechanical components that demand high fatigue resistance like crankshafts, cam shafts, bearing caps and clutch housings. The impact of various process parameters like the depth of cut, cutting speed and feed on the surface roughness (Ra) of SG iron is studied and optimized using the response surface model. The chip morphology is also discussed for evaluation of the quality of the turned surface. The experimental outcomes reveal that the WC tool offers a high surface finish at the optimal combination of the cutting speed at 102 meter/minute, feed at 0.051 millimeter/revolution and depth of cut at 0.5 millimeter and that, for the CBN insert, at 245 meter/minute of cutting speed, 0.051 millimeter/revolution of feed and 0.75 millimeter of depth of cut.

The effect of substrate surface roughness on the nucleation of cubic boron nitride films

2006 ◽  
Vol 15 (1) ◽  
pp. 55-60 ◽  
Author(s):  
C.Y. Chan ◽  
S. Eyhusen ◽  
X.M. Meng ◽  
I. Bello ◽  
S.T. Lee ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Substrate Surface ◽  
Cubic Boron Nitride ◽  
Substrate Surface Roughness ◽  
Boron Nitride Films

Surface Roughness Optimization in End Milling of Stainless Steel AISI 304 with Uncoated WC-Co Insert Under Magnetic Field

2012 ◽  
Vol 576 ◽  
pp. 119-122 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Syidatul Akma Sulaiman ◽  
Siti Noor Izzati Mohd Zainun ◽  
M.D. Arif
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Magnetic Fields ◽  
Permanent Magnets ◽  
End Milling ◽  
Desirability Function ◽  
Low Carbon Steel ◽  
Machining Process ◽  
Low Carbon ◽  
Novel Approach

Chatter phenomenon is a major issue as it greatly affects the topography of machined parts. Due to the inconsistent character of chatter, it is extremely difficult to predict resultant surface roughness in a machining process, such as end milling. Also, recent studies have shown that chatter can be suitably damped using magnetic fields. This paper, thus, focuses on a novel approach of minimizing surface roughness in end milling of Mild (Low Carbon) Steel using uncoated WC-Co inserts under magnetic field from permanent magnets. In this experiment, Response Surface Methodology (RSM) approach using DESIGN EXPERT 6.0 (DOE) software was used to design the experiments. The experiments were performed under two different cutting conditions. The first one was cutting under normal conditions, while the other was cutting under the application of magnetic fields from two permanent magnets positioned on opposite sides of the cutter. Surface roughness was measured using Mitutoyo SURFTEST SV-500 profilometer. The subsequent analysis showed that surface roughness was significantly reduced (by as much as 67.21%) when machining was done under the influence of magnetic field. The experimental results were then used to develop a second order empirical mathematical model equation for surface roughness and validated to 95% confidence level by using ANOVA. Finally, desirability function approach was used to optimize the surface roughness within the limiting values attainable in end milling.

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