scholarly journals The Tool Life of Ball Nose end Mill Depending on the Different Types of Ramping

2014 ◽  
Vol 22 (341) ◽  
pp. 115-121
Author(s):  
Tomáš Vopát ◽  
Jozef Peterka ◽  
Martin Kováč
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Measurement Process ◽  
Depth Of Cut ◽  
End Mill ◽  
Cutting Tool Wear ◽  
Different Types ◽  
Measuring Machine ◽  
Copy Milling

Abstract The article deals with the cutting tool wear measurement process and tool life of ball nose end mill depending on upward ramping and downward ramping. The aim was to determine and compare the wear (tool life) of ball nose end mill for different types of copy milling operations, as well as to specify particular steps of the measurement process. In addition, we examined and observed cutter contact areas of ball nose end mill with machined material. For tool life test, DMG DMU 85 monoBLOCK 5-axis CNC milling machine was used. In the experiment, cutting speed, feed rate, axial depth of cut and radial depth of cut were not changed. The cutting tool wear was measured on Zoller Genius 3s universal measuring machine. The results show different tool life of ball nose end mills depending on the copy milling strategy.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Influence of Edge Preparation on Cutting Tool Wear

2012 ◽  
Vol 201-202 ◽  
pp. 1178-1181
Author(s):  
Guo Bing Chai ◽  
Wei Wang ◽  
Ai Bing Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Impact Resistance ◽  
Cutting Tools ◽  
Medium Carbon Steel ◽  
Cutting Edge ◽  
Cutting Tool Wear ◽  
Edge Radius ◽  
Edge Preparation

Edge preparation is not only the process of grinding proper geometry of cutting edge or removing micro-cracks on cutting edge region, but also a way of improving cutting tool life. In this study, cutting models with different cutting edge radius were set up with FEM software. Medium carbon steel cutting tests were carried out using cutting tools with different edge radius. Cutting tool wear was simulated and measured for comparison. The simulation results show that edge radius has influences on tool wear. Tool cutting behavior is concerned with edge radius. A proper edge radius will improve the tool life. The experimental results show that proper edge preparation could improve tool impact resistance capability and reduce tool wear. The cutting tool life can be prolonged with suitable edge preparation. Edge preparation can improve cutting performance of cutting tool.

scholarly journals Analysis of The Tool-Chip Interface Temperature In Cryogenic Hard Turning of Aisi D6 Tool Steel

2021 ◽  
Author(s):  
Edmilson Dantas de Lima ◽  
Anderson Clayton Alves De Melo ◽  
Adilson José de Oliveira ◽  
Júlio César Giubilei Milan ◽  
Álisson Rocha Machado
Keyword(s):  
Tool Wear ◽  
Liquid Nitrogen ◽  
Tool Steel ◽  
Hard Turning ◽  
Cutting Tool ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Promising Alternative ◽  
Cutting Tool Wear

Abstract Hard turning is considered a strong candidate to partially replace grinding in finishing operations. However, as in the grinding operation, hard turning produces high temperatures that contributes to accelerate the cutting tool wear. In order to minimize this effect, cutting fluids can be applied as an alternative, even when PCBN inserts are used as cutting tools. However, there are many drawbacks associated with the use of cutting fluids, particularly those of mineral base, as they are hazardous to the environment. In this context, the need for more eco-friendly cutting fluids is growing and liquid nitrogen (LN2) offers a promising alternative. Previous studies have shown that LN2 can significantly reduce the cutting tool wear rate in comparison with other cooling strategies, and this is normally attributed to a reduction in the tool-chip interface temperature. However, investigations on the tool-chip interface temperature in cryogenic machining are scarce in the literature, particularly with regard to the turning of tool steels, and this study was performed to partially fill this gap. The tool-chip interface temperature during the turning of quenched and tempered AISI D6 tool steel, under dry conditions and using LN2, was investigated. A tool-workpiece thermocouple system was developed for this purpose and calibrated using a data acquisition system based on the low-cost Arduino Uno platform. In the turning tests, liquid nitrogen was delivered at the tool flank face of PCBN inserts at three cutting speeds with a constant feed rate and depth of cut. The results showed that LN2 was effective in reducing the tool-chip interface temperature at the lowest cutting speed; however, when this cutting parameter was increased, the reduction in the interface temperature was minimal as compared with the dry condition.

Performance of Brazed Carbide End Mill Tool for Machining of Ti6Al4V

2014 ◽  
Vol 541-542 ◽  
pp. 363-367 ◽  
Author(s):  
Saad Nawaz ◽  
Li Xiao Xing ◽  
Zhou Chai
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Thermal Stresses ◽  
Elevated Temperatures ◽  
Aerospace Industry ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Depth Of Cut ◽  
End Mill

Titanium alloys are attractive materials for aerospace industry due to their exceptional strength to weight ratio that is maintained at elevated temperatures and their good corrosion resistance. Major applications of Titanium alloys were military aerospace industry, but since last decade the trend has now shifted towards commercial industry. On the other hand Titanium alloys are notorious for being poor thermal conductor that leads to them being difficult materials for machining. In this experimental study brazed carbide end mill of grade 5 is used for rough down milling of Ti6Al4V for large depth of cut under different combinations of parameters and application of high pressure coolant. The machining performance was evaluated in terms of tool wear, tool life, thermal crack and tool breaking. The tool wear was mostly observed at the tool tip and at bottom part of tool thermal cracks were observed which propagated with respect to time. Flank wear due to scratching of the cutting chips and diffusion wear because of high thermal stresses were observed specially at the bottom of the cutting tool. At cutting speed of 38m/min tool wear couldnt be observed due to tool failure because of fracture under high thermal stresses. It was found that maximum tool life is obtained at the speed of 25m/min, feed rate of 150mm/min and depth of cut of 10mm. In the end it was concluded that machining of Ti6Al4V is a thermally dominant process which leads to high thermal stresses in machining zone that results in increasing tool wear rate and fracture propagation.

Technical Resource of the Cutting Wedge is the Foundation of the Machining Regime Determination

2020 ◽  
Vol 10 (2) ◽  
pp. 1-17 ◽  
Author(s):  
Viktor P. Astakhov ◽  
Stanislav V. Shvets
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Tool Wear ◽  
Work Done ◽  
Cutting System ◽  
Small Tool

This article argues that cutting tool wear is not just a particular case of wear found in general machinery because the whole amount of energy required for cutting is transmitted through relatively small tool-chip and tool-workpiece interfaces causing extremely high contact temperatures and pressures. This article discusses a considerably different approach to the determination of the cutting speed based upon the energy passing through the cutting wedge. Moreover, it discusses that, for a given tool material/geometry, there is a limited amount of such energy that the cutting wedge can sustain before reaching the criterion of tool life. This limit is considered as the technical resource of the cutting tool. The article establishes and verifies the existence of the detect correlation between the works done in the cutting system and in tool wear. Based on this finding, the equations to calculate the cutting speed for a chosen tool life and/or the tool life for a chosen cutting speed are proposed. The concept of the technical resource of the cutting wedge is introduced as the total amount of work done before it fails.

Influence of CAM Strategies on the Wear of Cutting Tools

2016 ◽  
Vol 834 ◽  
pp. 90-95
Author(s):  
Rudolf Zaujec ◽  
Peter Pokorný
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Milling Process ◽  
Cnc Milling ◽  
Cutting Tool Wear ◽  
Digital Microscope ◽  
Measuring Machine

This paper presents research on the influence of CAM strategies for wear and durability of milling tools. We used two machining principles in this process. In the first instance was constant point of contact with the tool and machining surface. The second method was changing point of the cutting edge in the milling process. Material of tool was hard alloy and high speed steel for machining steel 40CrMnMo7 and C45. The shape of cutting tool was a “Ball Nose” end mill. A DMU 85 monoBLOCK 5-axis CNC milling machine was used. The cutting tool wear was measured in Zoller Genius 3, universal measuring machine and digital microscope, Dino lite 2. The results show differences of cutting tool wear depending on the milling strategy and material of tool.

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