Cutting Performance of Coated Cemented Carbide Tool in Driven Rotary Cutting of Hardened Steel

2019 ◽  
Vol 13 (1) ◽  
pp. 49-57 ◽  
Author(s):  
Hideharu Kato ◽  
Noriyuki Takase ◽  
Kentaro Watanabe ◽  
Tatsuya Shikimura ◽  
Kazuyuki Kubota ◽  
...  
Keyword(s):  
Oxidation Resistance ◽  
High Speed ◽  
High Efficiency ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Processing Efficiency ◽  
High Cutting Speed ◽  
Rotary Cutting ◽  
Coated Cemented Carbide

Recently, cutting has replaced grinding in the finishing process for hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high-feed rate conditions rather than more conventional cutting conditions. Therefore, a new cutting technique that can realize high-efficiency cutting is desired. In our previous study, the processing efficiency was improved three to five times compared with conventional hardened steel cutting by driven rotary cutting. Furthermore, to attain high efficiency, the resistance of the tool material to wear and oxidation must be improved. In this study, the cutting performance of tools with an Al-rich coating, which improves oxidation resistance, is investigated for high cutting speed applications. In the present experiments, the flank wear of the Al-rich tool was less than 40 μm at a high cutting speed of 2.51 m/s, even for a cutting length of 10.0 km. Additionally, the Al-rich tool wear advanced progressively without flaking. In contrast, the conventional TiAlN-coated tools exhibited serious failure at cutting lengths of 3.0 km. It is thought that the difference in the oxidation resistance of the two tools influenced the cutting performance. Therefore, the tool with the Al-rich coating can operate with a high efficiency even at high cutting speeds.

A Study on Driven-Type Rotary Cutting for Finish Turning of Carburized Hardened Steel

2012 ◽  
Vol 523-524 ◽  
pp. 250-255 ◽  
Author(s):  
Hideharu Kato ◽  
Tatsuya Shikimura ◽  
Yoshitaka Morimoto ◽  
Kazuhiro Shintani ◽  
Toshio Inoue ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
High Efficiency ◽  
Single Point ◽  
Hardened Steel ◽  
Cutting Edge ◽  
Finish Turning ◽  
Cutting Length ◽  
Rotary Cutting

Recently, cutting has replaced grinding in the finish processing of hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high feed rate conditions instead of the present cutting conditions. Therefore, the examination of a new cutting technique that can realize high-efficiency cutting is desired. In this study, the effects and efficiency of driven rotary cutting are investigated in the finish turning of carburized hardened steel. Based on the results, flaking occurs at the cutting edge at a short cutting length of 0.2 km using single-point turning. On the other hand, even if the cutting length amounts to 1.5 km, the tool wear width without flaking is small in the case of a driven rotary tool. Additionally, the tool wear is uniformly distributed along the circumference of the cutting edge. Furthermore, based on an examination of high-efficiency processing by increasing the feed rate, it is clarified that a feed rate of 0.3 mm/rev is the optimum condition from the viewpoint of wear resistance and surface roughness. Additionally, even if the cutting length amounts to 5.0 km for this condition, the flank wear width is as small as 0.04 mm, and the tool wear progresses gradually.

scholarly journals Study on High-Efficiency Finish Turning of Carburized Hardened Steel with Driven Rotary Cutting

2013 ◽  
Vol 7 (3) ◽  
pp. 321-328 ◽  
Author(s):  
Hideharu Kato ◽  
◽  
Tatsuya Shikimura ◽  
Yoshitaka Morimoto ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
High Efficiency ◽  
Single Point ◽  
Hardened Steel ◽  
Cutting Edge ◽  
Finish Turning ◽  
Cutting Length ◽  
Rotary Cutting

Recently, cutting has replaced grinding in the finish processing of hardened steel. However, tool damage is a major problem in high-efficiency operations that use high-speed cutting and high-feed rate conditions instead of the present cutting conditions. Therefore, the examination of a new cutting technique that can realize high-efficiency cutting is desired. In this study, the effects and efficiency of driven rotary cutting are investigated in the finish turning of carburized hardened steel. Based on the results, flaking occurs when single-point turning is used at the cutting edge at a short cutting length of 0.2 km. On the other hand, even if the cutting length amounts to 5.0 km, the tool wear width without flaking is small in the case of driven rotary cutting. Additionally, the tool wear is uniformly distributed along the circumference of the cutting edge. Furthermore, based on an examination of high-efficiency processing by increasing the feed rate, it is found that a feed rate of 0.3 mm/rev is the optimum condition from the viewpoint of wear resistance and surface roughness. Additionally, even if the cutting length amounts to 5.0 km for this condition, the flank wear is as narrow as 0.04 mm, and the tool wear progresses gradually.

Cutting Performance and Wear Mechanism of Si3N4-Based Nanocomposite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 324-329 ◽  
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Jin Peng Song
Keyword(s):  
Wear Resistance ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Tool Materials ◽  
High Cutting Speed ◽  
The Matrix

Si3N4/TiN nanocomposite tool and Si3N4/Ti(C7N3) nanocomposite tool were prepared. The cutting performance and wear mechanism of Si3N4-based nanocomposite ceramic tool was investigated by comparison with a commercial sialon ceramic tool in machining of 45 steel. Si3N4-based nanocomposite ceramic tool exhibits the better wear resistance than sialon at the relatively high cutting speed. The increased cutting performance of Si3N4-based nanocomposite ceramic tool is ascribed to the higher mechanical properties. Nano-particles can refine the matrix grains and improve the bonding strength among the matrix grains of Si3N4-based nanocomposite ceramic tool materials. It contributes to an improved wear resistance of the cutting tools during machining.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Optimization of High Speed Milling Cutter Based on Critical Cutting Speed

2008 ◽  
Vol 392-394 ◽  
pp. 793-797
Author(s):  
Bin Jiang ◽  
Min Li Zheng ◽  
Fang Xu
Keyword(s):  
High Speed ◽  
Influencing Factor ◽  
Cutting Speed ◽  
Optimization Method ◽  
Face Milling ◽  
Cutting Performance ◽  
Feed Speed ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Cutting Heat

Based on analyses of cutting heat and temperature in high speed milling, to construct a model of critical cutting speed for high speed milling cutter, find out influencing factor of critical cutting speed, and put forward optimization method of high speed milling cutter based on critical cutting speed. The results indicate that chip conducts a majority of cutting heat along with increase of cutting speed, feed speed and the rake of cutter. Cutting heat which workpiece conducts gradually diminishes when heat source accelerates. When cutting performance of cutter satisfies requirements of high speed milling, the proportion of cutting heat which workpiece conducts approaches its maximum as cutting speed comes to critical cutting speed. To optimize high speed face milling cutter for machining aluminum alloy according to critical cutting speed, the cutter takes on better cutting performance when cutting speed is 2040m/min~2350m/min.

scholarly journals Cutting Performance Evaluation of the Coated Tools in High-Speed Milling of AISI 4340 Steel

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3266 ◽  
Author(s):  
Yuan Li ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Xianhai Yang ◽  
Rufeng Xu ◽  
...  
Keyword(s):  
Performance Evaluation ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Coated Tools ◽  
Coated Tool ◽  
Aisi 4340

The cutting performance of cutting tools in high-speed machining (HSM) is an important factor restricting the machined surface integrity of the workpiece. The HSM of AISI 4340 is carried out by using coated tools with TiN/TiCN/TiAlN multi-coating, TiAlN + TiN coating, TiCN + NbC coating, and AlTiN coating, respectively. The cutting performance evaluation of the coated tools is revealed by the chip morphology, cutting force, cutting temperature, and tool wear. The results show that the serration and shear slip of the chips become more clear with the cutting speed. The lower cutting force and cutting temperature are achieved by the TiN/TiCN/TiAlN multi-coated tool. The flank wear was the dominant wear form in the milling process of AISI 4340. The dominant wear mechanisms of the coated tools include the crater wear, coating chipping, adhesion, abrasion, and diffusion. In general, a TiN/TiCN/TiAlN multi-coated tool is the most suitable tool for high-speed milling of AISI 4340, due to the lower cutting force, the lower cutting temperature, and the high resistance of the element diffusion.

Study on Cutting Performance and Wear Mechanisms of Graded Ceramic Tool

2014 ◽  
Vol 490-491 ◽  
pp. 358-361
Author(s):  
Yan Zheng Li ◽  
Zhong De Shan ◽  
Jun Zhao ◽  
Jing Yun Xiong
Keyword(s):  
Ductile Iron ◽  
Wear Mechanisms ◽  
High Speed ◽  
Nickel Content ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Ceramic Tool ◽  
Dry Cutting ◽  
Short Segment ◽  
Graded Ceramic Tool

In this paper, based on the experiments of high speed dry cutting nickel alloyed ductile iron with different nickel contents by graded ceramic tool, the cutting performance and wear mechanisms of graded ceramic tool were investigated. Results reveal that with the increase of cutting speed and nickel content the wear of graded ceramic tool is increased, wear mechanisms are transformated spalling and cohesive wear from abrasive wear, and chip shapes are turned into long arc segment from short segment.

Tool Wear of Polycrystalline Cubic Boron Nitride Compact Tools in Cutting Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 724-728 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Boron Nitride ◽  
Tool Wear ◽  
Tool Life ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Cbn Tool ◽  
High Cutting Speed

Using polycrystalline cubic boron nitride compact (cBN) tools, which have different cBN contents and cBN particle sizes, the influences of both the cBN content and the cBN particle size on tool wear in turning of hardened steel at various cutting speeds was experimentally investigated. Three types of cBN tools (a cBN content of 45-55% and 75%, and a cBN particle size of 0.5 μm and 5 μm, respectively) were tested. Furthermore, three kinds of chamfered and honed cutting edges were also used. The main results obtained are as follows: (1) In the case of the cBN tools with the same cBN particle size of 5.0 μm, the tool life of the cBN tool with a cBN content of 75% was longer than that of the cBN tool with a cBN content of 45% at low cutting speed. However, at high cutting speed, the tool life of the cBN tool with a cBN content of 75% was shorter. (2) The tool life of the cBN tool with both a cBN content of 55% and a cBN particle size of 0.5 μm was the longest. (3) The tool wear of cBN tools decreased with a decrease in chamfer width.

Modelling and characterisation of roughness of moulds produced by high-speed machining with ball-nose end mill

2016 ◽  
Vol 231 (6) ◽  
pp. 933-944 ◽  
Author(s):  
Marcelo Ferreira Batista ◽  
Alessandro Roger Rodrigues ◽  
Reginaldo Teixeira Coelho
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Surface Damage ◽  
Double Effect ◽  
Hardened Steel ◽  
Numerical Control ◽  
High Speed Machining ◽  
End Mill ◽  
Kinematic Singularity ◽  
Dimensional Errors

Cusps and scallops of hardened steel moulds produced by high-speed milling using a ball-nose end mill were mathematically modelled, characterised by microscopy and experimentally validated. The experimental results show that the part material is crushed or ploughed near the cutter centre, where the cutting speed is very low. This kinematic singularity, associated with tool feed, compresses and bends the ball-nose end mill axially. Because of this double effect, the end mill marks on the part at the end of the milling path cause surface damage and dimensional errors to the hardened mould. A mathematical model may predict the formation of the cusps and scallops and be of use in computer numerical control or computer-aided manufacturing programming to obtain the desired part topography.

Cutting Forces in High Speed Milling of Hardened Steel by Coated Tool

2009 ◽  
Vol 69-70 ◽  
pp. 418-422
Author(s):  
L.D. Wu ◽  
Cheng Yong Wang ◽  
D.H. Yu ◽  
Yue Xian Song
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Coated Tool ◽  
Radial Depth ◽  
Solid Carbide ◽  
End Mills

Hardened steel P20 at 50 HRC is milled at high speed by TiN coated and TiAlN coated solid carbide straight end mills, and the cutting forces and tool wear are measured. The result shows that TiAlN coated tool is more suitable for cutting hardened steel at high speed. Then the hardened steel is milled under different cutting parameters. It is indicated that the effect of cutting speed on cutting forces is small, but the effect of cutting speed on machine vibration should be considered. Increase feed per tooth or radial depth of cut will increase the cutting forces.

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