Strategies for Developing Milling Tools from the Viewpoint of Sustainable Manufacturing

2016 ◽  
Vol 10 (5) ◽  
pp. 727-736 ◽  
Author(s):  
A. M. M. Sharif Ullah ◽  
◽  
Takeshi Akamatsu ◽  
Masahiro Furuno ◽  
M. A. K. Chowdhury ◽  
...  
Keyword(s):  
Optimization Technique ◽  
Sustainable Manufacturing ◽  
Cutting Tools ◽  
Tool Material ◽  
Milling Tool ◽  
Cutting Velocity ◽  
High Feed ◽  
Material Energy ◽  
Sharp Corners ◽  
Milling Tools

This study addresses the strategies for developing the cutting tools used in the material removal process called milling from the viewpoint of sustainable manufacturing. Sustainable manufacturing can be achieved by improving the material, energy, and component efficiencies, simultaneously. Cutting tools are just as important as machine tools and process planning to the achievement of the abovementioned efficiencies. Accordingly, this study describes two strategies based on high cutting velocity and feed per revolution, respectively. Exercising the strategy of high cutting velocity requires a Monte Carlo simulation-driven optimization technique. It helps make a balance between the tool material driven environmental burden and the user-defined maximum allowable cutting velocity. Exercising the strategy of high feed per revolution requires an innovative problem-solving procedure (e.g., TRIZ). It helps create novel solutions (e.g., an oval-shaped milling tool) that eliminate the causes of unstable cutting forces or vibrations when the tool passes over sharp corners. Thus, this study clearly shows that developing a milling tool from the viewpoint of sustainable manufacturing requires a multi-faceted approach. Similar strategies can be used to solve the problems involved in developing other cutting tools.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

Chip formation and the interaction of mesoscopic geometric features of cutter

2021 ◽  
pp. 095440542110284
Author(s):  
Xin Tong ◽  
Yanxiang Ren ◽  
Jianing Shen ◽  
Song Yu
Keyword(s):  
Synergistic Effect ◽  
Prediction Models ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Orthogonal Test ◽  
Cutting Performance ◽  
Geometric Features ◽  
High Quality ◽  
Milling Tool ◽  
Interaction Test

Most of the researches on the properties of micro-textured tools are based on an orthogonal test, while the interaction between micro-textured parameters is ignored. Therefore, this thesis is based on an interaction test to study the cutting performance of cutting tools. According to the chip morphology obtained from the interactive test, the micro texture diameter of 60 μm is obtained when the cutting is stable. It was also found that the synergistic effect of multiple mesoscopic geometric features had a significant influence on cutting performance. By analysis, we found the optimized parameters for the milling tool were D = 60 μm, l = 100 μm, l1 = 150 μm, r = 60 μm. Furthermore, prediction models of the cutting performance were established by univariate linear regression and the validity of these models was verified. Thus, this thesis provides a reference for improving the performance of cutting tools and for achieving efficient and high-quality machining of titanium alloys.

Forecasting Performance of Ceramic Cutting Tool

2017 ◽  
Vol 736 ◽  
pp. 86-90 ◽  
Author(s):  
Vyacheslav Maksarov ◽  
A. Khalimonenko
Keyword(s):  
Electrical Resistance ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
Ceramic Materials ◽  
Specific Electrical Resistance ◽  
Testing Methods ◽  
Microstructural Parameters ◽  
Forecasting Performance ◽  
Nondestructive Testing Methods

The article considers the problems of forecasting the performance of cutting tools equipped with replaceable ceramic cutting bits. It is proposed to forecast the operability of ceramic tools on the ground of dependence between its performance characteristics and the microstructural parameters of the tool material. It is proposed to determine the parameters of ceramic bits microstructure by a nondestructive testing methods based on measuring the specific electrical resistance of ceramic materials. As a result of the study we have undertaken, a relationship was detected between the performance and specific electrical resistance of ceramic cutting tools.

scholarly journals Machining of Iron-Carbon Alloys by the Use of Poly-Crystalline Diamond Cutting Inserts with Internal Cooling

2018 ◽  
Vol 2 (3) ◽  
pp. 57 ◽  
Author(s):  
Manuel Reiter ◽  
Jens Brier ◽  
Friedrich Bleicher
Keyword(s):  
Wear Behavior ◽  
Cutting Tools ◽  
Tool Material ◽  
Internal Cooling ◽  
Diamond Cutting ◽  
Diffusion Effects ◽  
Cutting Inserts ◽  
Abrasive Cutting ◽  
Poly Crystalline Diamond ◽  
Insight Into

Poly-crystalline diamond (PCD) is an extremely tough, synthetically produced cutting tool material, which offers outstanding capabilities concerning wear behavior in abrasive cutting environments. Currently, the primary application of PCD cutting tools is the machining of non-ferrous materials, as the diamond’s carbon high affinity towards iron causes diffusion effects while cutting steel with rising temperature. This effect significantly reduces tool life. To lower the occurring temperature of the cutting process, and therefore avoid the reaction of carbon and iron, a thermal functionalization of the cutting inserts has been investigated. The results give insight into making PCD cutting tools economically usable for the machining of iron-carbon materials.

Cutting Performance and Wear Mechanisms of an Al2O3-Based Micro-Nano-Composite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 244-249 ◽  
Author(s):  
Yong Hui Zhou ◽  
Jun Zhao ◽  
Xing Ai
Keyword(s):  
Failure Modes ◽  
Cutting Tools ◽  
Tool Material ◽  
Composite Ceramic ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Nano Composite ◽  
Micro Particles ◽  
1045 Steel

An Al2O3-based composite ceramic cutting tool material reinforced with (W, Ti)C micro-particles and Al2O3 micro-nano-particles was fabricated by using hot-pressing technique, the composite was denoted as AWT. The cutting performance, failure modes and mechanisms of the AWT micro-nano-composite ceramic tool were investigated via continuous turning of hardened AISI 1045 steel in comparison with those of an Al2O3/(W, Ti)C micro-composite ceramic tool SG-4 and a cemented carbide tool YS8. Worn and fractured surfaces of the cutting tools were characterized by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). The results of continuous turning revealed that tool lifetime of the AWT ceramic tool was higher than that of the SG-4 and YS8 tools at all the tested cutting speeds. The longer tool life of the AWT composite ceramic tool was attributed to its synergistic strengthening/toughening mechanisms induced by the (W, Ti)C micro-particles and Al2O3 nano-particles.

Mikrofräswerkzeuge mit Schneiden aus cBN*/Micro-cutting tools with cBN cutters

2018 ◽  
Vol 108 (11-12) ◽  
pp. 773-777
Author(s):  
E. Uhlmann ◽  
J. Polte ◽  
M. Polte ◽  
Y. Kuche ◽  
H. Wiesner
Keyword(s):  
Surface Roughness ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
High Strength ◽  
Hardened Steel ◽  
Micro Milling ◽  
Geometric Accuracy ◽  
Micro Cutting ◽  
Core Technology ◽  
Milling Tools

Die Mikrozerspanung ist eine Kerntechnologie bei der Fertigung von Mikrospritzgussformen. Die hohen Ansprüche an die geometrische Genauigkeit und Oberflächenrauheit erfordern den Einsatz hochfester Werkstoffe. Jedoch unterliegen aktuelle Fräswerkzeuge bei der Mikrozerspanung einem hohen Verschleiß. Einen Lösungsansatz bietet der erfolgreich in der Makrozerspanung eingesetzte Schneidstoff kubisch-kristallines Bornitrid (cBN). Ziel der Untersuchungen war es daher, detaillierte Informationen zur Bearbeitung von gehärtetem Stahl mit cBN-Mikrofräswerkzeugen bereitstellen zu können.   Micro-cutting is a core technology for producing micro-injection moulds. High demands on geometric accuracy and surface roughness require high-strength materials. However, current milling tools for micro-cutting suffer from excessiv tool wear. A solution is offered by cutting materials based on cubic Boron Nitride (cBN), which have been used successfully in macro-machining. This article contains detailed information on the machining of hardened steel with micro-milling tools and cutting edges made of cBN.

scholarly journals Experimental study on the working performance of different milling tools for multistage fracturing ball seats

2020 ◽  
Vol 17 (6) ◽  
pp. 1699-1716
Author(s):  
Jia-Qi Che ◽  
Han-Xiang Wang ◽  
Yan-Wen Zhang ◽  
Ming-Chao Du ◽  
Shao-Hua Ma
Keyword(s):  
Wear Resistance ◽  
Large Diameter ◽  
Cutting Speed ◽  
Bottom Surface ◽  
Analysis Model ◽  
Abrasive Grain ◽  
Milling Tool ◽  
Working Performance ◽  
Milling Tools ◽  
Working Efficiency

AbstractTo achieve the secondary production in multistage fracturing wells of tight oil, milling tools are usually used to remove the multistage fracturing ball seats to achieve production with a large diameter in later. In this paper, first of all, the working mechanism of milling tools for multistage fracturing ball seats was studied and a mechanical analysis model of single abrasive grain was established. Then, an experimental system for milling tools was developed, and the experimental tests of the flat, the blade, and the slope milling tool were conducted in order. Besides, the morphology of chips and the surface morphology of the workpiece after the experiment were analyzed. Also, the working performance of milling tools was evaluated from the perspectives of working safety, working efficiency, and wear resistance of the milling tool. The results show that the torque of the milling tool increases nonlinearly with the increase in the cutting depth of the abrasive grain and increases linearly with the increase in the cutting width. Also, the chips are irregular particles and the size is mainly from 10 to 50 μm. So, the chips should be pumped up with a small pump pressure and a large displacement. Besides this, the cutting depths of the abrasive grains are from 216.20 to 635.47 μm and the bottom surface of the milling tool should be eccentric to avoid the zero point of cutting speed. Furthermore, the torque of the slope milling tool is 23.8% larger than that of the flat milling tool, which is also 30.4% smaller than that of the blade milling tool. Compared with the flat milling tool, the working efficiency of the blade milling tool improves by 79.9% and the slope milling tool improves by 111.1%. Also, the wear resistance of the blade milling tool decreases by 102.7%, while the slope milling tool declines by 32.6% when compared with the flat milling tool. Therefore, the slope milling tool has the characteristics of moderate torque, stable working conditions, the highest working efficiency, and fine wear resistance, which is preferably used to mill multistage fracturing ball seats. This study provides a theoretical basis and guidance for milling multistage fracturing ball seats on-site and realizing production with a large diameter in later stages of multistage fracturing wells.

Study on Micro Milling Tool with Hot-Pressed Sintered Ti(C7N3)-Based Cermet

2016 ◽  
Vol 693 ◽  
pp. 906-913
Author(s):  
Kai Tao Xu ◽  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Hui Jun Zhou ◽  
Han Lian Liu ◽  
...  
Keyword(s):  
Static Load ◽  
Electrical Discharge Machining ◽  
Negative Impact ◽  
Micro Milling ◽  
Stress And Strain ◽  
End Mill ◽  
Milling Performance ◽  
Milling Tool ◽  
Minimum Stress ◽  
Milling Tools

Micro milling is most flexible to create 3D features for application. However, how to design and fabrication of high precision micro milling tools are one of big challenges for mechanical micro milling. Commercially available micro milling tools are usually simply made from downsizing of macro milling tools, which have negative impact on milling performance. Therefore, in this paper, firstly, various structural of micro milling tools were optimized with abaqus that investigated stress and strain under certain static load on the cutting edges. Then, results showed the minimum stress and strain was a micro hexagonal end mill. Finally, a Ti (C7N3) cermet micro hexagonal end mill with a radius of 0.5mm was fabricated by wire electrical discharge machining, and the evaluation experiments for the hexagonal mill have been processed on a micro milling centre.

Precision Cutting of Structured Ceramic Molds with Micro PCD Milling Tool

2011 ◽  
Vol 5 (3) ◽  
pp. 277-282 ◽  
Author(s):  
Hirofumi Suzuki ◽  
◽  
Tatsuya Furuki ◽  
Mutsumi Okada ◽  
Katsuji Fujii ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Polycrystalline Diamond ◽  
Micro Milling ◽  
Grinding Wheels ◽  
Form Accuracy ◽  
Structured Surfaces ◽  
Milling Tool ◽  
Milling Tools

Micro milling tools made of PolyCrystalline Diamond (PCD) have been developed to machine ceramic micro dies and molds. Cutting edges are ground with diamond wheels. PCD milling tool wear is evaluated by cutting binder-less tungsten carbide spherical molds and machining structured surfaces for trial. Results of experiments clarified that PCD milling tool life is over 10 times that of resinoid diamond grinding wheels, and that form accuracy was 0.1 µm-0.3 µm P-V and surface roughness was 10 nm Rz.

Precision Cutting of Ceramics with Milling Tool of Single Crystalline Diamond

2015 ◽  
Vol 9 (1) ◽  
pp. 26-32 ◽  
Author(s):  
Hirofumi Suzuki ◽  
◽  
Mutsumi Okada ◽  
Koichi Okada ◽  
Yosuke Ito ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Laser Beam ◽  
Tungsten Carbide ◽  
Micro Milling ◽  
Form Accuracy ◽  
Single Crystalline ◽  
Flat Shape ◽  
Ductile Mode ◽  
Milling Tool ◽  
Milling Tools

Micro milling tools made of Single Crystalline Diamond (SCD) have been developed to machine micro dies and molds made of ceramics. The milling tools of a cylindrical SCD having many sharp cutting edges are fabricated 3-dimensionally by scanning a laser beam. Flat shape of binder-less tungsten carbide mold was cut with the developed milling tool to evaluate the tool wears and its life. Some micro aspheric molds of tungsten carbide were cut with the milling tool at a rotational speed of 50,000 min-1. The ceramic molds were cut in the ductile mode. By cutting with the milling tool, the form accuracy obtained was about 100 nm P–V and the surface roughness 8 nm Rz.

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