Analysis of tool wear, surface roughness and cutting power in the turning process of compact graphite irons with different titanium content

The article compares two cutting edge preparation methods and their influence on the machined surface roughness of the difficult to cut nickel alloy Inconel 718 and the tool wear of cutting inserts made of cemented carbide. The manufacturing and preparation process of cutting inserts used in the experiment were made by Dormer Pramet. The preparation methods used in the experiment were drag finishing and brushing. Cutting parameters did not change during the whole turning process to maintain the same conditions in each step of the process and were determined based on tests for a semi-finishing operation of the turning process. To obtain durability of 25 to 30 minutes with controlled development of the tool wear the cutting parameters were determined with cooperation with the cutting inserts manufacturer.

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INVESTIGATION OF WIPER INSERTS EFFECTS IN TURNING AND MILLING PROCESSES

Surface Review and Letters ◽

10.1142/s0218625x21501110 ◽

2021 ◽

pp. 2150111

Author(s):

MURAT KIYAK

Keyword(s):

Surface Roughness ◽

Cost Saving ◽

Tool Wear ◽

Feed Rate ◽

Turning Process ◽

Nose Radius ◽

Turning Operations ◽

Effective Factors ◽

Milling Operations ◽

The Many

The surface roughness is a crucial factor in machining methods. The most effective factors on surface roughness are feed rate and tool nose radius. Due to the many advantages of wiper (multi-nose radius) inserts, their importance and use has been increasing recently. The purpose of this paper is to investigate the effect of wiper inserts on surface roughness and tool wear. In this study, conventional inserts and wiper inserts were experimentally compared separately in milling and turning operations. Compared to conventional inserts, the surface roughness values obtained using wiper inserts improved by 33% in turning operations and approximately 40% in milling operations. It was observed that the production time in the turning process was reduced by about 25% in the case of using wiper inserts compared to the use of conventional inserts. In milling, this ratio was determined to be approximately 43% due to the fact that it has multiple cutting edge. It has been observed that the use of wiper inserts in machining methods creates a significant time and cost saving advantage.

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Ultrasonic Assisted Diamond Turning of Hardened Steel for Mould Manufacturing

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.516.437 ◽

2012 ◽

Vol 516 ◽

pp. 437-442 ◽

Cited By ~ 9

Author(s):

Benjamin Bulla ◽

Fritz Klocke ◽

Olaf Dambon ◽

Martin Hünten

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Diamond Tool ◽

Spherical Geometry ◽

Diamond Turning ◽

Optical Surface ◽

Turning Process ◽

Shape Accuracy ◽

Ultrasonic Assisted ◽

Innovative Potential

Diamond turning of steel parts is conventionally not possible due to the high tool wear. However this process would enable several different applications with high economical innovative potential. One technology that enables the direct manufacturing of steel components with monocrystalline diamond is the ultrasonic assisted diamond turning process. This technology has been investigated over the years within the Fraunhofer IPT and is now commercialized by its spin-off company son-x. Surface roughness in the range of Ra < 5 nm can be achieved and the diamond tool wear is reduced by a factor of 100 or higher. In order to prove the industrial suitability of the process, two aspherical shapes and one large spherical geometry have been manufactured. The possible form accuracies and surface roughness values will be described in this paper, as well as the tool wear. The goal was to achieve optical surface roughness and a shape accuracy below 300 nm.

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