scholarly journals Comparision of Dominant Features Identification for Tool Wear in Hard Turning of Inconel 718 by Using Vibration Analysis

2019 ◽  
Vol 69 (4) ◽  
pp. 1-8
Author(s):  
Dasari Kondala Rao ◽  
Kolla Srinivas
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Hard Turning ◽  
High Hardness ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Absolute Deviation ◽  
Vibration Signals ◽  
Wear Process ◽  
Coated Carbide

AbstractIn various machining processes, the vibration signals are studied for tool condition monitoring often referred as wear monitoring. It is essential to overcome unpredicted machining trouble and to improvise the efficiency of the machine. Tool wear is a vital problem in materials such as nickel based alloys as they have high hardness ranges. Though they have high hardness, a nickel based alloy Inconel 718 with varying HRC (51, 53, and 55), is opted as work material for hard turning process in this work. Uncoated carbide, coated carbide and ceramic tools are employed as cutting tools. Taguchi’s L9 orthogonal array is considered by taking hardness, speed, feed and depth of cut as four input parameters, the number of experiments and the combinations of parameters for every run is obtained. The vibration signals are recorded at various stages of cutting, till the tool failure is observed. Taking this vibration signal data as input to ANOVA and Grey relation analysis (GRA) which categorizes the optimal and utmost dominant features such as Root Mean Square (RMS), Crest Factor (CF), Skewness (Sk), Kurtosis (Ku), Absolute Deviation (AD), Mean, Standard Deviation (SD), Variance, peak, Frequency and Time in the tool wear process.

scholarly journals Tool Condition Monitoring in Hard Turning of Inconel 718 by using Vibration Technique

2019 ◽  
Vol 8 (11) ◽  
pp. 1143-1147
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Inconel 718 ◽  
Hard Turning ◽  
High Hardness ◽  
Tool Condition Monitoring ◽  
Depth Of Cut ◽  
Vibration Signals ◽  
Tool Condition ◽  
Coated Carbide

In various machining processes, the vibration signals are studied for tool condition monitoring often referred as wear monitoring. It is essential to overcome unpredicted machining trouble and to improvise the efficiency of the machine. Tool wear is a vital problem in materials such as nickel based alloys as they have high hardness ranges. Though they have high hardness, a nickel based alloy Inconel 718 with varying HRC (51, 53, and 55), is opted as work material for hard turning process in this work. Uncoated and coated carbide tools are employed as cutting tools. Taguchi’s L9 orthogonal array is considered by taking hardness, speed, feed and depth of cut as four input parameters, the number of experiments and the combinations of parameters for every run is obtained. The vibration signals are recorded at various stages of cutting, till the tool failure is observed. Taking this vibration signal data as input to ANOVA and Grey relation analysis (GRA) which categorizes the optimal and utmost dominant features such as Root Mean Square (RMS), Crest Factor (CF), Skewness (Sk), Kurtosis (Ku), Absolute Deviation (AD), Mean, Standard Deviation (SD), Variance, peak, Frequency and Time in the tool wear process

scholarly journals Mathematical modelling of dominant features identification for tool wear monitoring in hard turning by using Acoustic emission

2021 ◽  
Vol 12 (2) ◽  
pp. 935-943
Author(s):  
D. Kondala Rao, Et. al.
Keyword(s):  
Mathematical Modeling ◽  
Acoustic Emission ◽  
Tool Wear ◽  
Simulated Data ◽  
Information Criterion ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Wear Monitoring ◽  
Grey Relational ◽  
Coated Carbide

In machining processes generally tool wear will be obtained with varying proportions. In the present work, the number of dominant features, which affect the tool wear, are studied and computed on Inconel 718 as work material with varying hardness (51, 53&55HRC) levels. The condition monitoring was done on three tools namely uncoated carbide, coated carbide and ceramic tools. By using L9 Taguchi’s orthogonal array, speed, feed, depth of cut (DOC) and hardness are considered as input operating parameters. By indirect method of Acoustic emission (AE) technique, signals were collected using Lab VIEW software and dominating features were calculated using the MATLAB. The features were trained in neural network and got the relation between tool wear, surface roughness, temperature and features. The simulated data was analyzed by Grey relational analysis (GRA) and the dominating features ranking sequence was obtained   for all the three tools and same ranking was also observed with ANOVA. Since there are no common influencing features among these three tools and hence further investigation continued with statistical mathematical modeling. With Akaike information criterion a mathematical model is developed to find the dominant features. By mathematical modeling the sequence in evaluating tool wear was found to be Kurtosis, Frequency, Variance, Mean and RMS and also a relation between tool wear and dominant features was developed which can be readily used by layman for calculating the tool wear.

Tool Wear of PVD Coated Carbide Tool when Finish Turning Inconel 718 under High Speed Machining

2010 ◽  
Vol 129-131 ◽  
pp. 1004-1008 ◽  
Author(s):  
M.Z.A. Yazid ◽  
C.H. Che Hassan ◽  
A.G. Jaharah ◽  
A.I. Gusri ◽  
M.S. Ahmad Yasir
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Nose Radius ◽  
Machining Processes ◽  
Finish Turning ◽  
Diffusion Wear ◽  
Flank Face ◽  
Coated Carbide

This paper reports the results of an experimental works, where Inconel 718, a highly corrosive resistant, nickel-based super alloy, was finish-turning under high speed conditions. The machining processes were carried out at three different cutting conditions (DRY, MQL 50 ml/h and MQL 100 ml/h), three levels of cutting speed (Vc=90, 120 and 150 m/min), two levels of feed rate (f=0.10 and 0.15 mm/rev) and two levels of cutting depth (d=0.30 and 0.50 mm). The tool wear and flank wear progression were monitored, measured and recorded progressively at various time intervals. The experiments indicated that MQL condition performs better than dry condition in term of tool life. Most of the tool failures during machining were due to gradual failure where abrasive and notching wear on the flank face was the dominant followed by, fracture on the flank edge and nose radius. Tool failure due to crater wear was not significant. Wear mechanism such as abrasive and adhesion were observed on the flank face and diffusion wear was observed on the rake face.

Investigation on Wear Behavior and Chip Formation During Up-Milling and Down-Milling Operations for Inconel 718

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
M. A. Hadi ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Inconel 718 ◽  
End Milling ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Milling Operations ◽  
Milling Operation ◽  
Coated Carbide

A comprehensive study and FEM simulation of ball nose end milling on tool wear behavior and chip formation had been performed on Inconel 718 (nickle-based superalloy) under minimum quantity lubricant (MQL) condition. In this paper, the investigation was focusing on the comparison of up-milling and down-milling operations using a multi-layer TiAlN/AlCrN-coated carbide inserts. A various cutting parameters; depth of cut, feed rate and cutting speed were considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear compared to up-milling operation. Chipping on cutting tool edge responsible to notch wear with prolong machining. It was observed that the chips formed in up-milling operation were segmented and continuous, meanwhile down-milling operation produced discontinuous type of chips.

Experimental Investigation on Tool Wear when End-Milling Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 410-415 ◽  
Author(s):  
Yuan Wei Wang ◽  
Jian Feng Li ◽  
Z.M. Li ◽  
Tong Chao Ding ◽  
Song Zhang
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Coated Carbide ◽  
Carbide Inserts

In this paper, some experiments were conducted to investigate tool wear when end-milling Inconel 718 with the TiAlN-TiN PVD coated carbide inserts. The worn tools were examined thoroughly under scanning electron microscope (SEM) with Energy Dispersive X-ray Spectroscopy and 3D digital microscope to expatiate tool wear morphologies and relevant mechanisms. The flank wear was uniformity in finishing milling process, and the average flank wear were selected as the criterion to study the effects of cutting parameters (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) on tool wear. Finally, the optimal combination of the cutting parameters for the desired tool life is obtained.

scholarly journals Analysis of vibration signals to quantify displacement amplitude in the monitoring of vibration-assisted turning

2017 ◽  
Vol 233 (1) ◽  
pp. 35-47 ◽  
Author(s):  
Balla Srinivasa Prasad ◽  
Javvadi Umamaheswara Rao ◽  
A Gopala Krishna
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Real Time ◽  
Feed Rate ◽  
Laser Doppler Vibrometer ◽  
Vibration Signal ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Vibration Signals ◽  
Coated Carbide

Vibration-assisted machining combines precision machining with small-amplitude tool vibration at high frequency to improve the fabrication process. It has been applied to a number of processes from turning to drilling to grinding. This work presents the validation of tool condition monitoring system based on vibration parameters. For this purpose, an experimental investigation is planned to acquire vibration signal data during the machining. This work primarily focuses on quantifying the presence of relative vibrations between the cutting tool and a workpiece during vibration-assisted turning process which helps in predicting tool life. For this purpose, an online acoustic optic emission-based vibration transducer, i.e. Laser Doppler Vibrometer, is used as a component of a novel approach. Cutting force and vibration signals were recorded and analyzed. Machine dynamic effects such as cutting force and tool wear are taken into account during the dry machining of Ti-6Al-4V alloys specimens. Identifying the correlation among tool wear, cutting forces and displacement due to vibration is a critical task in the present study. Real-time experimental findings are used to predict the evolution of displacement and tool wear in the experiment. Efficacy of a logical relationship among the process variables such as displacement, feed rate, spindle rotational speed, and depth of cut is critically examined. Results of the present study are used to establish a strategy for real-time efficient tool monitoring systems for vibration-assisted turning operation. The wear mechanisms of DNMA 432 coated carbide and uncoated carbide insert tools were examined at different combinations of feed rate, spindle speed, and depth of cut for turning of Ti-6Al-4V workpiece material.

Tool Wear Analysis in End Milling of Advanced Ceramics with TiAlN and TiN Coated Carbide Inserts

2012 ◽  
Vol 576 ◽  
pp. 76-79
Author(s):  
M. Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein ◽  
D. Sujan ◽  
Mohammad Yeakub Ali ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
High Hardness ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Carbide ◽  
Axial Depth

Advanced ceramic materials are difficult to machine by conventional methods due to the brittle nature and high hardness. The appropriate selection of cutting tool and cutting conditions may help to improve machinability by endmilling. Performance of TiAlN and TiN coated carbide tool insert in end milling of machinable glass ceramic has been investigated. Several dry cutting tests were performed to select the optimum cutting parameters for the endmilling in order to obtain better tool life. In this work, a study was carried out on the influence of cutting speed, feed rate and axial depth of cut on tool wear.The technique of design of experiments (DOE) was used for the planning and analysis of the experiments. Tool wear prediction model was developed using Response surface methodology.The results indicate that tool wear increased with increasing the cutting speed and axial depth of cut. Effect of feed rate is not much significant on selected range of cutting condition

Tool Wear of PVD Coated Carbide Inserts in High Speed Turning Inconel 718

2010 ◽  
Vol 26-28 ◽  
pp. 988-992
Author(s):  
Xin Yu Song ◽  
Jun Zhao
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
High Speed ◽  
High Hardness ◽  
High Wear Resistance ◽  
Coating Delamination ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Notch Wear

TiAlN/TiN multilayer PVD coated carbide is one of the dominant tool materials for the turning applications of Inconel 718 due to its high hardness, high wear resistance, and high thermal stability. The results of a thorough investigation on TiAlN/TiN multilayer PVD coated carbide inserts were presented for turning Inconel 718. The tool wear of the PVD coated carbide inserts were tested and analyzed at different cutting speeds from 50m/min to 90m/min and different feed rates from 0.1mm/r to 0.4mm/r. The wear patterns and wear mechanisms of PVD coated carbide were analyzed. Results show that the dominant wear patterns are rake face wear, flank wear, micro-chipping, coating delamination, notch wear, built-up edge and breakage. The main wear mechanisms are adhesion, diffusion, abrasive and oxidation.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

Sign in / Sign up

Export Citation Format

Share Document