Study on cutting performance of SiCp/Al composite using textured tool

2021 ◽  
Author(s):  
Xu Wang ◽  
Valentin L. Popov ◽  
Zhanjiang Yu ◽  
Yiquan Li ◽  
Jingkai Xu ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Contact Length ◽  
Cutting Performance ◽  
Surface Residual Stress ◽  
Machined Surface ◽  
Micro Cutting ◽  
Al Composite ◽  
Micro Hole ◽  
Pulsed Fiber Laser ◽  
Secondary Cutting

Abstract In the micro cutting process of SiCp/Al composites, the tool wear is serious due to the existence of reinforcement phase in the material, which greatly affects the machined surface integrity. In order to reduce the friction and adhesion at the tool-chip interface, fabricating micro texture on the tool surface could be a feasible solution. This work focuses on the study of the cutting performance of the textured cutting tools through micro cutting of SiCp/Al composites. The experiments were carried out using NTK-KM1CCGW060202H uncoated cemented carbide tools with micro-hole textures developed by pulsed fiber laser. The results indicate that the micro-textured tools can reduce the wear, sticking and the contact length between the tool-chip. Also, the surface quality can be improved. It is observed from the chip’s surface that the micro-textured tool can produce secondary cutting when machining SiCp/Al composite materials, the smaller the texture spacing, the more obvious the secondary cutting phenomenon. Furthermore, the cutting forces can be reduced using the micro-textured tool in most cases. However, when the texture spacing is too small the cutting force does not decrease. Finally, the surface roughness and surface residual stress of the machined workpiece are investigated. Textured tools have better results.

scholarly journals Study on cutting performance of SiCp/Al composite using textured YG8 carbide tool

2021 ◽  
Author(s):  
Xu Wang ◽  
Valentin L. Popov ◽  
Zhanjiang Yu ◽  
Yiquan Li ◽  
Jinkai Xu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Cutting Performance ◽  
Precision Machining ◽  
Surface Residual Stress ◽  
Sic Particles ◽  
Al Composite ◽  
Cutting Length ◽  
Three Body ◽  
Secondary Cutting

AbstractPrecision machining of SiCp/Al composites is a challenge due to the existence of reinforcement phase in this material. This work focuses on the study of the textured tools’ cutting performance on SiCp/Al composite, as well as the comparison with non-textured tools. The results show that the micro-pit textured tool can reduce the cutting force by 5–13% and cutting length by 9–39%. Compared with non-textured tools, the cutting stability of the micro-pit textured tools is better. It is found that the surface roughness is the smallest (0.4 μm) when the texture spacing is 100 μm, and the residual stress can be minimized to around 15 MPa in the case of texture spacing 80 μm. In addition, the SiC particles with size of around 2–12 μm in the SiCp/Al composite may play a supporting role between the texture and the chips, which results in three-body friction, thereby reducing tool wear, sticking, and secondary cutting phenomenon. At the same time, some SiC particles enter into the micro-pit texture, so that the number of residual particles on the surface is reduced and the friction between the tool and the surface then decreases, which improves the surface roughness, and reduces the surface residual stress.

Experimental Assessment of Laser Textured Cutting Tools in Dry Cutting of Aluminum Alloys

2016 ◽  
Vol 138 (7) ◽  
Author(s):  
Youqiang Xing ◽  
Jianxin Deng ◽  
Xingsheng Wang ◽  
Kornel Ehmann ◽  
Jian Cao
Keyword(s):  
Aluminum Alloys ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Cutting Performance ◽  
Rake Face ◽  
Dry Cutting ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Chip Compression Ratio ◽  
Cemented Carbide Tools

To improve the friction conditions and reduce adhesion at the tool's rake face in dry cutting of aluminum alloys, three types of laser surface textures were generated on the rake face of cemented carbide tools. Orthogonal dry cutting tests on 6061 aluminum alloy tubes were carried out with the textured and conventional tools (CT). The effect of the texture geometry on the cutting performance was assessed in terms of cutting forces, friction coefficient, chip compression ratio, shear angle, tool adhesions, chip morphology, and machined surface quality. The results show that the textured tools can improve the cutting performance at low cutting speeds, and that the tool with rectangular type of textures is the most effective.

Fabrication and cutting performance of cemented tungsten carbide micro-cutting tools

2011 ◽  
Vol 35 (4) ◽  
pp. 547-553 ◽  
Author(s):  
Kai Egashira ◽  
Shigeyuki Hosono ◽  
Sho Takemoto ◽  
Yusuke Masao
Keyword(s):  
Tungsten Carbide ◽  
Cutting Tools ◽  
Cutting Performance ◽  
Micro Cutting ◽  
Cemented Tungsten Carbide

scholarly journals Investigation on Cutting Performance of Micro-Textured Cutting Tools

Micromachines ◽  
2019 ◽  
Vol 10 (6) ◽  
pp. 352 ◽  
Author(s):  
Qinghua Li ◽  
Chen Pan ◽  
Yuxin Jiao ◽  
Kaixing Hu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Performance ◽  
Rake Face ◽  
Machined Surface ◽  
Element Analysis ◽  
Machined Surface Roughness ◽  
Micro Hole ◽  
Pcbn Tools ◽  
Cutting Experiments

This paper explores the influence of micro textures on cutting performance of polycrystalline cubic boron nitride (PCBN) tools from two aspects, that is, tool wear and machined surface roughness. By designing micro-hole textures with different forms and scales on the rake face of tools when PCBN tools turn hardened steel GCr15, and combining finite element analysis (FEA) technology and cutting experiments, the cutting performance of micro-textured tools is simulated and analyzed. This paper analyses the influence of micro textures on tool wear and machined surface roughness by analyzing cutting force, Mises stress and maximum shear stress of tool surface. Results of finite element analysis (FEA) and cutting experiments show that the reasonable micro-hole textures can significantly alleviate tool wear and improve machined surface quality when compared with the non-textured tools. Besides, the size of micro-hole textures on the rake face play an important role in reducing the cutting force and tool wear. This is mainly because micro-hole textures can reduce cutting force and improve tool surface stress. Finally, by designing reasonable micro-hole textures on the rake face, the problems of bad roughness of machined workpiece and severe tool wear of PCBN tools in cutting GCr15 material are solved. Consequently, the paper shows that micro-hole textures have a positive effect on improving the cutting performance of tool.

Improvement of thread turning process using micro-hole textured solid-lubricant embedded tools

2021 ◽  
pp. 095440542110199
Author(s):  
Salman Khani ◽  
Seyedhamidreza Shahabi Haghighi ◽  
Mohammad Reza Razfar ◽  
Masoud Farahnakian
Keyword(s):  
Surface Roughness ◽  
Mechanical Strength ◽  
Solid Lubricant ◽  
Operating Cost ◽  
Contact Length ◽  
Solid Lubrication ◽  
Turning Process ◽  
Micro Holes ◽  
Micro Hole ◽  
Cutting Inserts

In this paper, the thread turning of aluminum 7075-T6 alloy is studied using micro-hole textured solid-lubricant embedded carbide inserts. The primary focus of this work is to enhance the performance of the thread turning process for producing high quality threaded parts. To achieve this, micro-holes were generated by laser micro-machining on the rake face of tools and then, MoS2 and CNT (carbon nanotube) solid-lubricants were embedded into micro-holes. The effects of micro-holes and solid-lubrication on the performance of the thread turning process were examined using traditional tool ( T0), micro-hole textured tool ( T1), micro-hole textured MoS2 embedded tool ( T2), and micro-hole textured CNT embedded tool ( T3). In this study, cutting forces, chip-tool contact length, built-up edge (BUE), surface roughness, and operating cost were investigated. The influence of micro-hole generation on the mechanical strength of cutting inserts was evaluated using the finite element method. The results showed that the fabrication of the micro-holes on the rake surface of cutting inserts has no significant effect on the mechanical strength of the tools. The comparisons of our method with traditional tools demonstrated that the cutting performance improved in the threading process. Our results reveal that the main cutting force, radial thrust force, surface roughness, built-up edge, and chip-tool contact length reduced 37.1%, 40.9%, 37.9%, 58.3%, and 38.2%, respectively, as T3 tools are applied in this process. A cost analysis, based on estimated tooling costs, showed that the T3 tool can yield an 18% reduction in overall operating cost.

scholarly journals Feasibility of Cobalt-Free Nanostructured WC Cutting Inserts for Machining of a TiC/Fe Composite

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3432
Author(s):  
Edwin Gevorkyan ◽  
Mirosław Rucki ◽  
Tadeusz Sałaciński ◽  
Zbigniew Siemiątkowski ◽  
Volodymyr Nerubatskyi ◽  
...  
Keyword(s):  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machined Surface ◽  
Powder Consolidation ◽  
Plasma Sintering ◽  
Cutting Inserts ◽  
Spark Plasma ◽  
And Performance ◽  
Nanostructured Tungsten Carbide

The paper presents results of investigations on the binderless nanostructured tungsten carbide (WC) cutting tools fabrication and performance. The scientific novelty includes the description of some regularities of the powder consolidation under electric current and the subsequent possibility to utilize them for practical use in the fabrication of cutting tools. The sintering process of WC nanopowder was performed with the electroconsolidation method, which is a modification of spark plasma sintering (SPS). Its advantages include low temperatures and short sintering time which allows retaining nanosize grains of ca. 70 nm, close to the original particle size of the starting powder. In respect to the application of the cutting tools, pure WC nanostructure resulted in a smaller cutting edge radius providing a higher quality of TiC/Fe machined surface. In the range of cutting speeds, vc = 15–40 m/min the durability of the inserts was 75% of that achieved by cubic boron nitride ones, and more than two times better than that of WC-Co cutting tools. In additional tests of machining 13CrMo4 material at an elevated cutting speed of vc = 100 m/min, binderless nWC inserts worked almost three times longer than WC-Co composites.

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.

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.

The Effect of Oxygen Addition on Oxidation Resistance and Cutting Performance of Si3N4 Ceramics

2007 ◽  
Vol 534-536 ◽  
pp. 1089-1092
Author(s):  
Mituyoshi Nagano ◽  
Hideaki Sano ◽  
Shigeya Sakaguchi ◽  
Guo Bin Zheng ◽  
Yasuo Uchiyama
Keyword(s):  
Bending Strength ◽  
Cutting Tools ◽  
Cutting Performance ◽  
Al2o3 Content ◽  
High Wear Resistance ◽  
Composition Analysis ◽  
Performance Improvements ◽  
Oxygen Addition ◽  
Effect Of Oxygen ◽  
Si3n4 Ceramics

The effect of oxygen addition on oxidation behavior of the β-Si3N4 ceramics with 5 mass% Y2O3 and 2 or 4 mass% Al2O3 was investigated by performing oxidation tests in air at 1300° to 1400°C and cutting performance tests. These tests were intended to clarify their ware resistance as cutting tools. The results of mass change, SEM observation and composition analysis of the specimens before and after oxidation test showed that as the Al2O3 content in the β-Si3N4 ceramics increased, mass changes resulted higher oxidation during which process pores and cracks formed due to the release of N2 gas. The values of hardness and bending strength of the specimens with relatively small amount of 2 mass% Al2O3, which formed solid solution in the Si3N4 structure [Si6-zAlzOzN8-z (z = 0.1)], showed larger than those of the specimen with 4 mass% Al2O3 (z = 0.2). The specimens group added with Al2O3 of 2 mass% (Z = 0.1) also showed high wear resistance. From this, we could conclude that the mechanical properties of β-Si3N4 ceramics depending on oxygen introduction is much effective on cutting performance improvements of the cutting performance of β-Si3N4 ceramics.

scholarly journals The Comparative Study on Cutting Performance of Different-Structure Milling Cutters in Machining CFRP

2018 ◽  
Vol 8 (8) ◽  
pp. 1353
Author(s):  
Tao Chen ◽  
Fei Gao ◽  
Suyan Li ◽  
Xianli Liu
Keyword(s):  
Carbon Fiber ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Edge ◽  
Cutting Performance ◽  
Machining Process ◽  
Carbon Fiber Composites ◽  
Machined Surface ◽  
Milling Cutter ◽  
Machined Surface Quality

Carbon fiber reinforced plastic (CFRP) is typically hard to process, because it is easy for it to generate processing damage such as burrs, tears, delamination, and so on in the machining process. Consequently, this restricts its wide spread application. This paper conducted a comparative experiment on the cutting performance of the two different-structure milling cutters, with a helical staggered edge and a rhombic edge, in milling carbon fiber composites; analyzed the wear morphologies of the two cutting tools; and thus acquired the effect of the tool structure on the machined surface quality and cutting force. The results indicated that in the whole cutting, the rhombic milling cutter with a segmented cutting edge showed better wear resistance and a more stable machined surface quality. It was not until a large area of coating shedding occurred, along with chip clogging, that the surface quality decreased significantly. At the stage of coating wear, the helical staggered milling cutter with an alternately arranged continuous cutting edge showed better machined surface quality, but when the coating fell off, its machined surface quality began to reveal damage such as groove, tear, and fiber pullout. Meanwhile, burrs occurred at the edge and the cutting force obviously increased. By contrast, for the rhombic milling cutter, both the surface roughness and cutting force increased relatively slowly.

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