Comparison of the machinability of the 316L and 18Ni300 additively manufactured steels based on turning tests

2021 ◽  
pp. 146442072110149
Author(s):  
Tiago EF Silva ◽  
Ana Amaral ◽  
André Couto ◽  
João Coelho ◽  
Ana Reis ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mechanical Strength ◽  
316L Stainless Steel ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Chip Breaker ◽  
Tool Geometries ◽  
Longitudinal Turning ◽  
Chip Geometry ◽  
Cutting Speeds

This paper focuses on the machinability of additively manufactured steel alloys (316L stainless steel and 18Ni300 Maraging steel) by reference to their conventional metallurgical conditions. The machinability of both metallurgical conditions has been evaluated by longitudinal turning tests under laboratory conditions using two different cutting tool geometries (flat rake face and chip-breaker geometry) and covering different cutting speeds, depths of cut and feed values. Cutting forces, chip morphology and surface roughness were investigated as machinability indicators. The influence of chip-breaker on process performance was also analysed. For a comprehensive discussion of the results, microstructure, chemical composition, surface roughness and mechanical strength of both metallurgical conditions were studied. The paper quantitatively demonstrates that despite the higher mechanical strength of additively manufactured alloys, no significant power requirements were verified for the finishing cutting of tested alloys, when compared with conventional materials. Also noteworthy, is the surface quality improvement of the printed samples due to the most favourable conditions for chip formation. The usage of a chip breaker insert had higher impact on reducing required cutting energy than on controlling chip geometry.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

Theoretical Value of Total Height of Profile in Rotational Turning

2013 ◽  
Vol 309 ◽  
pp. 154-161 ◽  
Author(s):  
István Sztankovics ◽  
János Kundrák
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Edge ◽  
Technological Parameters ◽  
Machined Surface ◽  
Total Height ◽  
Roughness Profile ◽  
Rotational Turning ◽  
Longitudinal Turning ◽  
Chip Removal

The roughness of the machined surface is determined by the kinematics of chip removal, the shaping and the geometry of the cutting edge. The change of the surface roughness in cutting done under different conditions is easy to follow examining the theoretical value of roughness characteristics. This paper examines how the extent of the theoretical value of total height of profile depends on the different technological parameters in rotational turning. Furthermore the surface roughness and roughness profile is compared achievable by rotational turning and traditional longitudinal turning (in case of radius and pointed cutting tool).

The Effect of Build Up Edge Formation on the Machining Characteristics in Austempered Ferritic Ductile Iron

2013 ◽  
Author(s):  
Şakir Yazman ◽  
Ahmet Akdemir ◽  
Mesut Uyaner ◽  
Barış Bakırcıoğlu
Keyword(s):  
Surface Roughness ◽  
Ductile Iron ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Salt Bath ◽  
Chip Formation Mechanism ◽  
Machining Properties ◽  
Machining Characteristics ◽  
Cutting Speeds

In this study, chip formation mechanism during the machining of austempered ferritic DI and the effect of the emerging chip morphology on such machining properties as surface roughness and cutting forces has been scrutinized. After austenitizing at 900 °C for 90 min, DI specimens were austempered in a salt bath at 380 °C for 90 min. Chip roots were produced by using a quick stop device during the machining of austempered specimens in different cutting speeds. The metallographies of these specimens were performed and chip morphologies were examined. The fact that the cutting speed increased led to a decrease in built-up edge formation. Depending on this fact, it was detected that the change in built-up edge thickness substantially affected the surface roughness and cutting forces. It was also detected that during the machining, with the effect of cutting forces and stress, spheroidal graphites were broken off in the chip and lost their sphericity and so that the chip became fragile and unstable and grafites here displayed a lubricant feature.

Evaluation of the cutting forces, the surface roughness, and the tool wear characteristics during machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool

2021 ◽  
pp. 095440892110480
Author(s):  
Abdullah Altin
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Signal To Noise ◽  
Ceramic Cutting Tool ◽  
Cutting Speeds

In this research, we had studied the sensitivity for machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool. The investigation had focused on the effects of the cutting speed, on the cutting forces, and on the surface roughness based on Taguchi’s experimental design. The effects of machining parameters were determined using Taguchi’s L27 orthogonal array. The signal-to-noise ratio was calculated for the average of surface roughness and the cutting forces, and the smaller were used to determine the optimal cutting conditions. The analysis of variance and the signal-to-noise ratio had effects on the parameters on both surface roughness and cutting. Three different types of cutting tools had been used in the experiment, namely KYON 4300, KYS 25, and KYS 30. The cutting force of Fz was considered to be the main cutting force. Depending on the material which had been used as cutting tool, the Fz had the lowest cutting speed and the lowest surface roughness with the KYS25 ceramic tool. The cutting force and the surface roughness of KYON 4300 cutting tool had shown better performance than other cutting tools. The flank wear and notch were found to be more effective in the experiments. The long chips were removed at low and medium cutting speeds, while the sawdust with one edge and narrow pitch at high cutting speeds was obtained.

Analytical Modeling of Chip Geometry in High-Speed Ball-End Milling on Inclined Inconel-718 Workpieces

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Harshad A. Sonawane ◽  
Suhas S. Joshi
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
End Milling ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Shear Angle ◽  
Analytical Models ◽  
Ball End Milling ◽  
Cutting Mechanisms ◽  
Chip Geometry

Most often contoured surfaces inclined at several inclinations are generated using ball-end milling of aerospace and automobile components. It is understood that the chip morphology and the corresponding cutting mechanisms change with a change in the tool-workpiece interactions on inclined surfaces. Analytical predictive models to accurately evaluate the undeformed and deformed geometries of chip in ball-end milling are not available. Therefore, this work presents development of analytical models to predict the cutting tool-workpiece interaction as the workpiece inclination changes, in terms of undeformed and deformed chip cross sections. The models further evaluate instantaneous shear angle along any cross section of the tool-work interaction on a ball-end cutter in a milling operation. The models illustrate evaluation of a chip segment and mechanism of its formation in ball-end milling on an inclined work surface. It is observed that the chip dimensions, except deformed chip thickness, increase with an increase in the workpiece inclination angle. Also, a higher workpiece inclination results into an easy flow of the deformed chip over the cutting tool flank, which leads to a higher shear angle during the cut. The predictive chip geometry models corroborate 90% to the experimental results obtained at various workpiece inclinations.

Experimental Analysis of Ti6Al4V Orthogonal Cutting

2015 ◽  
Vol 665 ◽  
pp. 17-20 ◽  
Author(s):  
Apostolos Korlos ◽  
Orestis Friderikos ◽  
Dimitrios Sagris ◽  
Constantine David ◽  
Gabriel Mansour
Keyword(s):  
Formation Mechanism ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Serrated Chip ◽  
Wide Range ◽  
Chip Formation Mechanism ◽  
Serrated Chip Formation ◽  
Chip Geometry ◽  
Cutting Speeds

The chip formation mechanism in orthogonal cutting is a phenomenon that attracts the attention of many researchers. This paper investigates experimentally the orthogonal cutting of Ti6Al4V at different cutting conditions aiming at the understanding of the chip formation mechanism. Serrated chip formation is obtained during orthogonal cutting of Ti6Al4V in a wide range of cutting speeds. The results are analyzed in order to extract useful indices relevant to chip geometry, as the adiabatic zone angle and other dimensions that describe the serrated chip. The cutting forces and the acoustic emission are measured. Finally, by the aid of 3D Computed Tomography (CT) the chip morphology is analyzed to better understand the segmentation process.

Study on the Machinability of Free-Cutting Steels 1214 and 12L15 with Coated Tool

2012 ◽  
Vol 426 ◽  
pp. 151-154 ◽  
Author(s):  
Ying Ying Wei ◽  
Zhi Qiang Liu ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Environmental Friendly ◽  
Coated Tool ◽  
Orthogonal Tests

Research has been done on machinability of two different kinds of free-cutting steels by using coated cutting tool at the condition of different cutting parameters. Orthogonal tests are adopted in order to compare the cutting performance of the two materials. The cutting force, surface roughness, chip morphology and tool wear are investigated, which reveal the influence of Pb and other composition on machinability. The experiment shows that 1215 has more or less better performance than 12L14. It is of great significance for the development of environmental friendly products.

scholarly journals THE EFFECT OF THE CIRCULAR FEED ON THE SURFACE ROUGHNESS AND THE MACHINING TIME

2021 ◽  
pp. 70-76
Author(s):  
István Sztankovics
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Roughness Parameters ◽  
Machining Time ◽  
Edge Geometry ◽  
Cutting Experiments ◽  
Cutting Speeds

The surface roughness is analysed in different feeds and turning procedures (rotational and conventional) in this paper. Cutting experiments were made on different cutting speeds and feed rates with 2 cutting tool with helical edge geometry and 1 traditional turning tool. The measured 2D surface roughness values were compared between the different cutting tools. The benefit of the circular feed application is showed by the decrease of roughness parameters and machining time.

Investigation of the shearing length in the orthogonal turning of a steel AISI 1050

2020 ◽  
Vol 62 (8) ◽  
pp. 827-834
Author(s):  
Zülküf Demir
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Steel Material ◽  
Lathe Machine ◽  
Steel Aisi ◽  
Natural Mechanism ◽  
Impossible Task ◽  
Machining Operations

Abstract Vibration amplitudes in machining operations have a deteriorating influence on the outcomes of the processes. Moreover, eradicating them is an impossible task due to the natural mechanism of cutting metals. However, by selecting the optimum cutting parameters, the destructive effects of vibration amplitudes may be diminished to acceptable levels. In the present paper, AISI 1050 steel material was machined, employing carbide inserts and a CNC lathe machine. Cutting tool approaching angles were selected between -5° and 45°, feed rates from 0.1 mm × rev-1 to 0.5 mm × rev-1, cutting depths between 0.5 mm and 2.25 mm, and accordingly CSR values between 1 and 15. The effect of the selected parameters on the chip compression factor (CCF), shearing length feed (SLF), shearing length (SLA), surface roughness, and chip morphology was investigated. Moreover, the effect of CCF, SLF, and SLA on surface roughness, vibration amplitudes, and chip morphology was analyzed as well. It was found that the most influential parameter on shearing length was cutting depth while the feed rate was on the surface roughness. The optimum CCF values were between 1.7 and 2.3, SLF smaller than 1, and SLA around 5. Furthermore, it was shown that the optimum CSR values were 10 and 15, and cutting tool approaching angles 30° and 45°, according to the chip morphology criterion.

Performance Evaluation of Cryogenic Treated and Untreated Carbide Inserts during Machining of AISI 304 Steel

2020 ◽  
Vol 17 (1) ◽  
pp. 7709-7718
Author(s):  
Nagraj Patil ◽  
K. Gopalakrishna ◽  
B. Sangmesh
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cutting Tool ◽  
Cryogenic Treatment ◽  
Multilayer Coating ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Aisi 304 ◽  
Aisi 304 Steel

The cutting tool in the machining process plays an important role as it acts on the working material. There are a few methodologies have been persued to improve tool life, for example traditional cooling, single layer coating, multilayer coating, heat treatment process, nitrogen cooling and latest being the cryogenic treatment which reported a significant improvement in cutting tool life, chip morphology, reduction in heat generation. Hence, the cryogenic treatment is emerged as the sustainable machining process.  This paper presents machining of AISI 304 steel using both cryogenic treated (CT) and untreated (UT) cutting tool insert. The commercially available uncoated carbide insert has been cryogenically treated at -196°C for 24 hours soaking period. The machining test has been  conducted under four different cutting speeds. The material characterization of cutting insert is studied by using scanning electron microscopy (SEM), hardness test, and microscopic image analysis has been carried out before and after cryogenic treatment. The cutting tool performance is assessed in terms of of wear, cutting temperature, chip morphology, surface roughness under the influence of cryogenic machining and the results are contrast with UT one. The exploratory findings reveals that the deep cryogenic treatment (DCT) with 24 hours soaking period, performed better wear resistance and improved surface roughness of the cutting tool. Also considerable reduction in the flank wear, crater wear, cutting temperature is obtained and found improved chip morphology.

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