Surface morphology and effect of cutting force and temperature in formation of the white layer during hard machining

2021 ◽  
Vol 23 (2) ◽  
pp. 113
Author(s):  
Deba Kumar Sarma ◽  
Sanjib Kr Rajbongshi
Keyword(s):  
Surface Morphology ◽  
Cutting Force ◽  
White Layer ◽  
Hard Machining

scholarly journals Cutting force based surface integrity soft-sensor when hard machining AISI 4140

2020 ◽  
Vol 87 (11) ◽  
pp. 683-693
Author(s):  
Markus Meurer ◽  
Berk Tekkaya ◽  
Thorsten Augspurger ◽  
Thomas Pullen ◽  
Daniel Schraknepper ◽  
...  
Keyword(s):  
Cutting Force ◽  
Layer Thickness ◽  
Analytical Model ◽  
White Layer ◽  
Element Model ◽  
Soft Sensor ◽  
Temperature Fields ◽  
Hard Machining ◽  
White Layer Thickness ◽  
Residual Stress State

AbstractWorkpiece rim zone modifications during hard machining can be explained with the high thermo-mechanical loads induced by the cutting process. The formation of White Layers with a fine-grained microstructure by dynamic recrystallization (DRX) is one of those surface modifications that can negatively affect the functionality of a machined part by changing the residual stress state and facilitating crack initiation. As a consequence, the fatigue life of the machined parts is reduced. It is therefore of great interest to understand the thermo-mechanical conditions which induce White Layers formation in order to be able to control them by in-situ measurements if necessary. For this purpose, a cutting force based Soft-Sensor is developed in this study which enables the in-process estimation of White Layer thickness. Therefore, a cutting force based analytical model is used to estimate the resulting temperature fields and correlated with validated numerical chip formation simulations. In addition, the predictions of the White Layer thickness of the analytical model are then compared using light microscopy and the results of the numerical finite element model, in which a DRX model is additionally implemented.

Dry Machining of Inconel 825 Superalloys

2021 ◽  
Vol 11 (4) ◽  
pp. 26-39
Author(s):  
Kshitij Pandey ◽  
Saurav Datta
Keyword(s):  
Tool Wear ◽  
Surface Morphology ◽  
Cutting Force ◽  
Carbide Tool ◽  
Dry Machining ◽  
Machining Performance ◽  
Force Magnitude ◽  
Wear Pattern ◽  
Inconel 825

The present work investigates application feasibility of PVD TiN/TiCN/TiN coated cermet and CVD Al2O3/TiCN coated SiAlON for dry machining of Inconel 825 superalloy. Machining performance is interpreted through cutting force magnitude, tool-tip temperature, and mechanisms of tool wear. Results are compared to that of CVD multi-layer TiN/TiCN/Al2O3/TiN coated WC-Co tool. It is evidenced that SiAlON tool generates lower cutting force but experiences higher tool-tip temperature than other two counterparts. Apart from abrasion and adhesion, carbide tool witnesses coating peeling and ploughing. In contrast, SiAlON tool suffers from inexorable chipping and notching. Wear pattern of cermet tool seems less severe than carbide and SiAlON. Chip's underside surface morphology appears relatively better in case of cermet tool.

Experimental studies of the cutting force and surface morphology of explosively clad Ti–steel plates

Measurement ◽  
2016 ◽  
Vol 78 ◽  
pp. 129-137 ◽  
Author(s):  
P. Nieslony ◽  
P. Cichosz ◽  
G.M. Krolczyk ◽  
S. Legutko ◽  
D. Smyczek ◽  
...  
Keyword(s):  
Surface Morphology ◽  
Cutting Force ◽  
Experimental Studies ◽  
Steel Plates

scholarly journals Study on Surface Quality and Corrosion Resistance of Ultrasonic Vibration Assisted Micromilling Inconel718

2021 ◽  
Author(s):  
Zhonghang Yuan ◽  
Bin Fang ◽  
Yude Dong ◽  
Heng Ding ◽  
Yuanbin Zhang
Keyword(s):  
Surface Roughness ◽  
Corrosion Resistance ◽  
Tool Wear ◽  
Surface Morphology ◽  
Cutting Force ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Machining Process ◽  
High Plasticity ◽  
Surface Corrosion

Abstract Micromilling (MM) is favored by the field of high-precision micro parts. However, the high plasticity of Inconel718 often poses a threat to MM, such as pits, humps and gullies, which affect the surface quality. In this study, the influence of ultrasonic vibration assisted micromilling (UVAMM) on surface quality is comprehensively analyzed by using the machining process of workpiece vibration, combined with cutting force, tool wear, surface morphology and corrosion resistance. The results show that, on the one hand, small amplitude plays a significant role in reducing cutting force and inhibiting tool wear. On the other hand, smaller speed, smaller feed rate and moderate amplitude will produce better surface morphology, which is a uniform and regular fish scale surface with lower surface roughness and fewer surface defects. Furthermore, the application of ultrasonic vibration also significantly improves the surface corrosion resistance of Inconel718. It is worth noting that the surface corrosion resistance does not completely depend on the surface roughness, but also has a close correlation with the surface morphology.

Micro-drilling of Mg-based MMCs reinforced with SiO2 nanoparticles: An experimental approach

2020 ◽  
Vol 234 (12) ◽  
pp. 1473-1485 ◽  
Author(s):  
Fuzhong Sun ◽  
Dehong Huo ◽  
Guoyu Fu ◽  
Xiangyu Teng ◽  
Sathish Kannan ◽  
...  
Keyword(s):  
Surface Morphology ◽  
Cutting Force ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Volume Fraction ◽  
Rotation Speed ◽  
Chip Thickness ◽  
Matrix Composites ◽  
Drilling Parameters ◽  
Micro Drilling

Mg-based metal matrix composites reinforced with nanoparticles are promising biomaterials due to their biocompatibility and high hardness and because they are local and systemic toxicity free. Nano-metal matrix composites are considered to be hard-to-machine materials due to the high strength and high abrasiveness of the reinforcing nanoparticles. In this article, the micro-drilling mechanisms of Mg-based metal matrix composites reinforced with different volume fraction of SiO2 nanoparticles (0.5, 1.0, 1.5, 2.0 vol.%) were investigated experimentally. Results obtained were also compared with pure Mg. First, it was found that the volume fraction and drilling parameters played an important role in the chip formation mechanism. Second, the influence of drilling parameters on hole surface morphology and cutting force were studied, in which both the rotation speed and feedrate affected the surface morphology, and the main factor affecting cutting force was found to be the feedrate. Furthermore, the formation of burrs was investigated. The height of the burr could be reduced by using small feedrate and low rotation speed. Finally, the size effect of micro-drilling was studied. The variation of surface roughness and cutting force of pure Mg and Mg-based metal matrix composites had three changing trends with the uncut chip thickness. The minimum chip thickness of Mg/SiO2 metal matrix composites was determined to be 1.1 μm.

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