Evaluation of Single Layer Hafnium Nitride Coated Tool for Metal Cutting

2016 ◽  
Vol 1815 ◽  
Author(s):  
John Henry Navarro Devia ◽  
Willian Aperador Chaparro ◽  
Jairo Cortes Lizarazo
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Single Layer ◽  
Numerical Control ◽  
Process Time ◽  
Work Piece ◽  
Hafnium Nitride

ABSTRACTThe main purpose of coatings is to increase the lifetime of cutting tools, to perform continuous and economical material removal process, reducing the frequency of sharpening or replacement of the tool, which contributes to increase quality of product. Therefore, hafnium nitride (HfN) single layer coatings were deposited on High-speed steel by Magnetron Sputtering physical vapour deposition (PVD). The machining on AISI 1020 steel samples were carried out in a computer numerical control (CNC) machine, using coated and uncoated tools, the temperature of the different components were measured (steel bar and tool), due to continuous temperature measurement help to predict tool wear and the quality of finished piece [1] . In order to evaluate wear resistance and performance, not only temperature data were compared, the tool wear morphological analysis for flank wear was carried using Scanning Electron Microscopy (SEM), and work pieces roughness were checked through their surfaces in an Atomic Force Microscopy (AFM). In most of the parameters evaluated differences between the tools were identified, and results reveals that on HfN coating, occurs less wear, due the proportionality between the energy transfer and the tool deterioration, also the coating improves surface finish of the machined part; all of them are reflected in changes on process temperatures. The use of single layer HfN coating on cutting tools could increase their lifetime, improve the quality of the work piece, and even reduce process time and cost.

scholarly journals Analyzing the Vibration Effect of Cutting Tool on Surface Roughness of Turning Work Piece in Lathe Machine

2021 ◽  
Vol 9 (VII) ◽  
pp. 1654-1657
Author(s):  
Sawant Akshay Shasheekant
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Metal Cutting ◽  
Experimental Testing ◽  
Cutting Tools ◽  
Work Piece ◽  
Vibration Signals ◽  
Observation Systems ◽  
Lathe Machine

Tool condition observation systems area unit essential in small milling applications. A tool's slenderness needs high-precision observation systems for on-line measurements. In most cases, tool health is indirectly calculable by process and analyzing the cutting method parameters cutlery wear may be a essential development that influences the standard of the machined half. Vibration signals from metal cutting processes are investigated for varied functions, together with in-process tool wear monitoring. Reducing the machining energy consumption (MEC) of machine tools for turning operations is important to market manufacturing producing. during this study, the link between vibration and gear wear is investigated throughout high-speed dry turning by victimization applied math parameters. it's aimed to show however tool wear and therefore the work piece surface roughness changes with tool vibration signals. For this purpose, a series of experiments were conducted in a lathe machine. Modal analysis of each traditional and wear cutlery are going to be perform for locating Natural frequency of cutting tools in ANSYS 19 code. Experimental testing of cutlery are going to be perform using FFT instrument. afterward the comparative analysis are going to be dispensed between the experimental and analysis results and afterward the result & conclusion are going to be drawn.

Experimental Investigation on the Effect of Tool Geometry and Cutting Conditions Using Tool Wear Prediction Model for End Milling Process

2014 ◽  
Vol 13 (01) ◽  
pp. 41-54 ◽  
Author(s):  
S. Kalidass ◽  
P. Palanisamy
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Condition ◽  
Machining Parameter

Tool wear of a cutting tool has a significant impact on the tool life and surface quality of the finished product. Tool wear is influenced by many factors such as cutting parameters, tool geometry, coating type, work piece material, chatter, and cutting condition. In the present work, the design of experiments (DOE) technique has been used for four factors at five levels to conduct experiments. Tool wear is taken as the response variable measured during end milling, while helix angle, spindle speed, feed and depth of cut are taken as the input parameters. The material and tool selected for this study are AISI 304 stainless steel and uncoated solid carbide end mill cutter respectively. The tool wear was measured using tool maker's microscope. The experimental values are used in six sigma software for finding the coefficients to develop the regression model. The direct and interaction effect of the machining parameter with tool wear were analyzed using contour graphs, which helped to select process parameters for reducing tool wear and also ensure quality of milling.

Tool Wear Estimation in Drilling Using Acoustic Emission Signal by Multiple Regression and GMDH

2008 ◽  
Author(s):  
L. J. Sudev ◽  
H. V. Ravindra
Keyword(s):  
Regression Analysis ◽  
Tool Wear ◽  
Machine Tool ◽  
Multiple Regression Analysis ◽  
Multiple Regression ◽  
Flank Wear ◽  
Cutting Tools ◽  
Regularity Criterion ◽  
Work Piece ◽  
Training Set

The cutting tool is the only element in a machine tool that requires frequent changes due to failure. Drill bit wear can cause catastrophic failure that can result in considerable damage to the work piece and the machine tool. Hence, there is an imperative need to keep a watch on the condition of the cutting tools during the machining process. Over the years, a wide variety of on-line or off-line techniques have been investigated for monitoring abnormal cutting tools. A variety of signals such as tool-tip temperature, forces, power, thrust, torque, vibrations, shock pulse, Acoustic Emission (AE) etc., have been used for monitoring tool failure by on-line technique. The detection and monitoring of AE is commonly used to predict tool failure. Present work involves estimation tool flank wear in drilling based on AE parameters viz., RMS, energy, signal strength, count and frequency by empirical methods of analysis like Multiple Regression Analysis and Group Method of Data Handling (GMDH). The experimental work consisted of drilling S.G Cast iron using high-speed steel drill bit and measuring AE parameters from the workpiece using AE measuring system for different cutting conditions. Machining was stopped at regular intervals of time and tool flank wear was measured by Toolmakers microscope. The experimental data were subjected to simpler methods of analysis to obtain a clear insight of the signals involved. The study of AE-time plots showed a similarity with three phases of tool wear, which implies that the measured AE parameters can be related to tool wear. Multiple Regression Analysis and Drilling is a major material removal process in manufacturing. Infact, the drills have been used widely in industry since the industrial revolution. It was estimated that 40% of all the metal removal operations in the aerospace industry is by drilling. Similar to the other cutting tools, after a certain limit, drill wear can cause catastrophic failure that can result in considerable damage to the work piece even to the machine tool [1]. GMDH methods were successful in estimating flank wear based on measured AE parameters. By Multiple Regression Analysis better estimation was obtained at lower cutting conditions. Three criterion functions of GMDH viz., Regularity, Unbiased and Combined were used for estimation with 50%, 62.5% and 75% of data in the training set. Estimation was done upto Level-4. The results of GMDH estimation showed that regularity criterion functions correlates well for the set of input variables compared with unbiased and combined criteria and least error of estimation was found when 75% of data was used in the training set. The optimum level of estimation increased with the increase in the percentage of data in the training set. Comparison of the performance of Multiple Regression Analysis and GMDH indicated that estimation by regularity criterion of GMDH had an edge over Multiple Regression Analysis.

scholarly journals Pengaruh Parameter Pemesinan terhadap Kualitas Hasil Potong Mesin Bubut Maximat V13 pada Benda Kerja Poros PVC

2019 ◽  
Vol 2 (02) ◽  
pp. 19-24
Author(s):  
Kasijanto Kasijanto ◽  
Sadar Wahjudi ◽  
Listiyono Listiyono ◽  
Muhammad Fakhruddin
Keyword(s):  
Metal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece ◽  
Machining Processes ◽  
Cutting Surface ◽  
Spindle Rotation ◽  
Feeding Speed ◽  
Tool Types

Metal cutting process (cutting process) is to cut metal to get the shape and size and quality of the planned cutting surface. The metal cutting process is carried out with special tools, according to the type of cutting process. So the tools for one process cannot be used in another process, even for similar processes, the tools cannot be exchanged if the cutting plans are not the same. Lathe process is a machining process to produce cylindrical machine parts which are carried out using a Lathe. Its basic form can be defined as the machining process of the outer surface of cylindrical or flat lathe objects. Polyvinyl Chloride, commonly abbreviated as PVC, is the third-order thermoplastic polymer in terms of total usage in the world, after Polyethylene (PE) and Polypropylene (PP). Worldwide, more than 50% of PVC produced is used in construction. PVC is produced by polymerizing vinyl chloride monomers (CH2 = CHCl). Because 57% of its mass is chlorine, PVC is the polymer that uses the lowest petroleum feedstock among other polymers. This research follows up the selection of configuration of the lathe machining process using plastic work pieces. In this study, Maximat V13 lathe and PVC type plastic were used. The variation of machining processes are spindle rotation (320, 540, and 900 rpm), feeding speed (0.07, 0.14, and 0.28), the use of tool types (carbide and HSS) and cooling (without cooling, coolant, and oil). So, with this research, it is expected that the optimal parameters in determining the configuration of the lathe machining process on a PVC work piece to produce a good turning surface can be achieved  

scholarly journals Analysis of the Performance of Drilling Operations for Improving Productivity

2021 ◽  
Author(s):  
Majid Tolouei-Rad ◽  
Muhammad Aamir
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Vital Role ◽  
Machining Process ◽  
Drilling Process ◽  
Single Shot ◽  
Drilling Operations

Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

scholarly journals Design and Development of a Three Component Milling Dynamometer

2021 ◽  
Vol 2070 (1) ◽  
pp. 012168
Author(s):  
Narender Maddela ◽  
Ch.Sai Kiran ◽  
Aluri Manoj ◽  
M. Kapila ◽  
B. Swapna ◽  
...  
Keyword(s):  
Tool Wear ◽  
Heat Generation ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Strain Gauges ◽  
Tool Geometry ◽  
Work Piece ◽  
Design And Development ◽  
Machined Surface

Abstract The cutting forces that are generated during metal cutting influence the work piece precision, tool wear, the nature of the machined surface, and heat generation. These cutting forces can be measured analytically however; precise outcomes may not be expected due to its included stresses, parameters of cutting, and the perplexing tool geometry. Henceforth the exploratory estimation of cutting forces is fundamental. For this reason, a milling dynamometer of three-segment is structured, created, and tried to gauge the three cutting forces which are produced during the operation of milling strain gauges can be utilized to quantify dynamic and static cutting forces through milling dynamometer. During the process of metal cutting, a dynamometer that is based on strain gauge is fit for estimating three-force segments. The dynamometer was designed based on the octagonal ring principle. The octagonal rings orientation and location of strain gauges have resolved to expand affectability and to limit cross-affectability.

Tribological Aspects of Metal Cutting

1993 ◽  
Vol 115 (3) ◽  
pp. 372-376 ◽  
Author(s):  
B. M. Kramer
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Chemical Properties ◽  
Work Piece ◽  
Metallic Surfaces ◽  
Tool Materials ◽  
Real Area Of Contact ◽  
Tribological System ◽  
High Pressure High Temperature ◽  
Physical And Chemical

The machining of metals presents a unique tribological situation in which atomically clean, metallic surfaces are cleaved from the interior of the workpiece and maintained in a condition of nearly 100 percent real area of contact with the tool surface during sliding. The conditions of high pressure, high temperature, and essentially uncontaminated contact during sliding create a highly ideal tribological system for analysis. As compared to conventional sliding wear, the analysis of which is complicated by multiple passes of the counterface materials and various forms of contamination and surface reaction, the predictive modeling of tool wear has achieved somewhat greater, if still modest, success. Current models of cutting tool wear are assessed with regard to their usefulness in developing quantitative analytical methods for designing new tool materials and for selecting optimum tool materials under variations in cutting conditions. Approaches which predict the relative wear resistances of potential tool materials from the physical and chemical properties of the tool-work-piece system, without recourse to calibration tests for each system, are emphasized.

Hardfacing of metal-cutting tools by arc welding in vacuum

2020 ◽  
Vol 2 (99) ◽  
pp. 49-56
Author(s):  
N.V. Ferdinandov ◽  
D.D. Gospodinov
Keyword(s):  
Wear Resistance ◽  
Heat Resistance ◽  
Arc Welding ◽  
High Speed ◽  
Metal Cutting ◽  
Microstructural Analysis ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Heat Treated ◽  
Better Than

Purpose: To present a technology for hardfacing of metal-cutting tools by arc welding in vacuum. Design/methodology/approach: The experiments were carried out using an installation for arc welding in vacuum. Objects of research were metal cutting tools (lathe knives), made of high-speed steel HS6-5-2 on a base metal of structural steel C45. The structure, hardness and wear resistance after hardfacing and after a triple tempering at 560°C have been determined. The heat resistance of the obtained instruments has been examined. Findings: The microstructural analysis showed that the structure of the built-up layer consisted of martensite, retained austenite and carbides. This was confirmed by the values of measured hardness after welding which were about 63-64 HRC. The triple tempering led to an increase in hardness by 3-4 HRC. It was found that the built-up layers (cutting edges of tools) retain their hardness (HRC=63-65) up to a temperature of 615-620°C, which shows that the heat resistance of the build-up layers was similar to that of the hardened and tempered tools of the same steel. The built-up work-pieces (excluding heat treated) and the reference knife showed the same cutting qualities at cutting speeds in the range of 55 to 120 m/min. It has been found that triple tempering after hardfacing led to increased wear resistance and consequently the durability of the tool also increased due to the higher hardness. Practical implications: The practical application is related to the production of metalcutting tools. Originality/value: The proposed technological method allows to produce defects free built-up layers. The cutting properties of the built-up in vacuum layers are comparable to or better than those of new tools made of steel HS 6-5-2.

Reliability Analysis of Cutting Tools

1979 ◽  
Vol 101 (2) ◽  
pp. 185-190 ◽  
Author(s):  
K. Hitomi ◽  
N. Nakamura ◽  
S. Inoue
Keyword(s):  
Tool Wear ◽  
Reliability Analysis ◽  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Reliability Function ◽  
Statistical Distribution ◽  
Experimental Results ◽  
Machining Parameters ◽  
Cutting Experiments

This paper is concerned with the reliability analysis of tool life based on the tool-wear values obtained from metal cutting experiments. From experimental results, a statistical distribution of tool wear was decided, and the distribution of tool life and the reliability function of cutting tools were derived. Further, it was shown that the reliability of cutting tools at a certain time was easily calculated from machining parameters and tool-wear limits by the use of reliability function.

Application of CBN Cutting Tools in Hard Turning and Tool Wear

2013 ◽  
Vol 690-693 ◽  
pp. 2022-2025
Author(s):  
Hai Dong Zhao ◽  
Li Bao An ◽  
Pei Qing Yang ◽  
Ye Geng
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Elevated Temperatures ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Specific Strength ◽  
Strength And Stiffness

Considerable research has been directed towards discovering new engineering materials for various applications. As a superhard material, Cubic Boron Nitride (CBN) has been developed and applied to engineering for several tens of years. Due to its high specific strength and stiffness as well as good creep, fatigue and wear resistance at elevated temperatures, CBN has been widely used as cutting tool material in manufacturing industry. In this paper, the preparation and characteristics of CBN are introduced. As hard turning has been more and more employed in recent years as an advanced metal cutting technique, the application of CBN cutting tools in hard turning is presented based on the literature, and in particular, the main wear mechanisms of CBN tools in hard turning are summarized, owing to the significant influence of tool wear on the tool life and product quality.

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