Experimental and Numerical Investigation of Tool Life of Single Point Cutting Tool during Turning Process

The hard turning process is widely used in automobile and heavy machinery industries. Extreme cutting conditions like high temperature and tool wear rate, are associated with the hard turning process. Cubic boron nitride (CBN) cutting tool is generally preferred for hard machining operations. However, higher tool cost, and tool failure due to thermal shock limits its widespread usage. In machining performance analysis, tool wear is an important parameter which is directly related to the cost of the machining process. Previous studies have reported the improvement in tool life by using cryogenic coolant as a cutting fluid. Objective of this paper is to investigate the effect of cryogenic cooling on the tool wear of CBN and Ti-coated alumina ceramic cutting tools used in the hard turning of AISI 52100 hardened steel. High pressure cryogenic jet (HPCJ) module was optimized and configured to use it for hard turning case. Computational fluid dynamics (CFD) based simulation was used to test and optimize the nozzle design for the flow of cryogenic coolant. It was validated by fundamental heat removal test. Ceramic and CBN cutting tools were then used for hard turning of parts using HPCJ module. Flank wear lengths for various cooling conditions were measured and analyzed. It was observed that the higher tool life of a Ti-coated alumina ceramic can be achieved under cryogenic cooling technique, as compared to the CBN insert under dry conditions. Cost analysis of these hard turning cases was also conducted to check the feasibility of its usage under realistic shop floor conditions. It was observed that the machining using Ti-coated ceramic under cryogenic jet may reduce the total tooling cost compared to CBN cutting tool conducted under dry conditions.

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Effect of Offset Distance on Cutting Forces and Heat Generation in Multi-Tool Turning Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.592-594.211 ◽

2014 ◽

Vol 592-594 ◽

pp. 211-215 ◽

Cited By ~ 2

Author(s):

R. Kalidasan ◽

M. Yatin ◽

D.K. Sarma ◽

S. Senthilvelan

Keyword(s):

Cutting Tool ◽

Gray Cast Iron ◽

Single Point ◽

Cutting Tools ◽

Cutting Speed ◽

Depth Of Cut ◽

Work Piece ◽

Turning Process ◽

Additional Tool ◽

Offset Distance

Productivity enhancement assumes a paramount importance in today’s competitive industrial world. The aim of this work is to improve productivity in a conventional lathe with two single point cutting tools machining a workpiece simultaneously. An additional tool holding fixture is fabricated and integrated so that distance between the two cutting tools can be varied and has a provision to provide individual depth of cut. Experiments were performed on gray cast iron workpiece at different offset distances between the cutting tools, at a particular cutting speed, feed rate and depth of cut. In the multi-tool turning process, lagging rear cutting tool experiences lesser cutting force than leading front cutting tool. This behaviour is due to the machining of front cutting tool preheat as well as reduction of effective cutting speed while machining with rear cutting tool. With increase in offset distance, moment acting on the work piece contributes to increase in resistance against machining and hence front tool experiences higher force than rear cutting tool.

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Evaluation of Tool Life Equation of Single-Point Cutting Tool by Accumulation Model

Lecture Notes in Mechanical Engineering - Proceedings of the 5th International Conference on Industrial Engineering (ICIE 2019) ◽

10.1007/978-3-030-22063-1_100 ◽

2019 ◽

pp. 943-951

Author(s):

A. V. Antsev ◽

N. I. Pasko ◽

A. V. Khandozhko

Keyword(s):

Tool Life ◽

Cutting Tool ◽

Single Point ◽

Accumulation Model

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Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

Materials Science Forum ◽

10.4028/www.scientific.net/msf.947.160 ◽

2019 ◽

Vol 947 ◽

pp. 160-166

Author(s):

Nutrada Khumjeen ◽

Somkiat Tangjitsitcharoen

Keyword(s):

Tool Life ◽

Feed Rate ◽

Cutting Tool ◽

Cutting Tools ◽

Cutting Speed ◽

Minimum Quantity Lubrication ◽

Cutting Fluid ◽

Cutting Condition ◽

Turning Process ◽

Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

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Development of an enhanced single point milling procedure to screen metalworking cutting fluid performance in terms of tool wear when machining aerospace alloys

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405420968159 ◽

2020 ◽

pp. 095440542096815

Author(s):

Thawhid Khan ◽

Matthew Broderick ◽

Syed Ashir Sajid ◽

Jack Secker ◽

Chris M Taylor

Keyword(s):

Tool Life ◽

Cutting Tool ◽

Low Cost ◽

Single Point ◽

Cutting Fluid ◽

Screening Tests ◽

Metalworking Fluids ◽

Suitable Candidate ◽

Aerospace Alloys ◽

Machining Test

Metalworking fluids (MWFs) can greatly improve the machinability of materials and increase cutting tool life. There are a range of MWF products available on the market, however there are very few reliable low cost machining based fluid screening tests which can help select the most suitable candidate. This study developed a novel and rigorous single point milling (SPM) procedure carried out under controlled conditions, which would provide fluid performance differentiation for a range of typical aerospace alloys. The use of a single insert with a controlled geometry reduced machining variance and ensured performance repeatability. Tool life curves were used to determine optimum machining surface speeds for Inconel 718 (In718) of 80 m/min and Ti-6Al-4V (Ti64) of 160 m/min. Carrying out trials using five different cutting fluid products within a controlled tool life window clearly demonstrated that the SPM machining test was able to differentiate performance on both In718 and Ti64 material. Overall a 65% and 53% performance difference in tool life behaviour was observed between the best and worst performing fluids for In718 and Ti64, respectively.

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