scholarly journals Analysis of the compromise between cutting tool life, productivity and roughness during turning of C45 hardened steel

2021 ◽  
Vol 27 (1) ◽  
pp. 30-35
Author(s):  
Youcef Abidi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Coefficient Of Determination ◽  
Depth Of Cut ◽  
Machining Productivity ◽  
Mixed Ceramic

Abstract Tool wear and surface roughness as performance indexes are considered to be the most important in terms of hardened materials’ machinability. The best combination of cutting parameters which enhances the compromise between tool life, productivity and machined surface quality contribute to benefice on production cost, which makes manufacturing industry interested in it. The aim of this research is to investigate the life of ceramic cutting tool and machining productivity together with surface roughness during turning of hardened steel C45, with focus on the selection of the optimal cutting parameter combination. The experiments are carried out based on uni-factorial planning methodology of cutting speeds and feed rates. The results show that the mixed ceramic tool is suitable for turning hardened steel C45 (40 HRC) and the conclusion is that it performed well in terms of tool life, productivity and surface quality at a combination of cutting speed (200 m/min), feed (0.08 mm/rev) and depth of cut (0.3 mm). Additionally, a tool life model has been proposed which is presented very high coefficient of determination.

scholarly journals Development of Surface Roughness in Hard Turning of 100Cr6 Using Mixed Ceramic Cutting Tool with Wiper Geometry and Conventional Geometry

2013 ◽  
Vol 21 (Special-Issue) ◽  
pp. 193-198
Author(s):  
Michaela Samardžiová ◽  
Miroslav Neslušan
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Hard Machining ◽  
Roughness Parameters ◽  
Ceramic Tool ◽  
Mixed Ceramic

Abstract Hard turning has been applied in machining since the early 1980s. There is an effort to substitute finish grinding by hard machining, because of machining by cutting tool with defined geometry. For machining of hardened steels (up to 45 HRC) are used two different cutting materials. PCBN are used the most for discontinuous machining of hardened steel (up to 63 HRC) and mixed ceramic tools, which are used in the experiment. This paper reports a development of surface roughness parameters when using wiper tool geometry of mixed ceramic tool and conventional geometry of mixed ceramic tool in hard turning. Roughness parameters (Ra, Rz, Rsk, Rku, RSm, Rdq) are measured when changing the feed, depth of cut and cutting speed are constant.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

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.

Deep Hole Machining with a Small Diameter Drill and Ultrasonic Vibration

2017 ◽  
Vol 749 ◽  
pp. 107-110
Author(s):  
Yuta Masu ◽  
Tomohito Fukao ◽  
Taiga Yasuki ◽  
Masahiro Hagino ◽  
Takashi Inoue
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Small Diameter ◽  
Maximum Amplitude ◽  
Depth Of Cut ◽  
Deep Hole ◽  
Work Material ◽  
Finished Surface

The method of imparting ultrasonic vibration to the cutting tool is known to improve the shape accuracy and finished surface roughness. However, a uniform evaluation of this function in drilling has not been achieved, and the cutting process cannot be checked from the outside. The aim of this study is to investigate the cutting characteristics in deep hole drilling when an ultrasonic vibrator on the table of a machining center provides vibration with a frequency of 20 kHz to the work piece. The ultrasonic vibrations in this system reach the maximum amplitude in the center of the work material. We evaluated the change in finished surface roughness between the section where drilling starts to the point of maximum amplitude with ultrasonic vibration. The main cutting conditions are as follows: cutting speed (V) 12.6 (mm/min); feed rate (s) 30, 60 (mm/rev); depth of cut (t) = 32 (mm); work material, tool steel; cutting tool material, HSS; point angle (σ) 118 (°); and drill diameter (φ) 4 (mm). Lubricant powder was also added to clarify the cutting effect, and compared the condition in which there was no ultrasonic vibration. The results showed that surface roughness at the point of maximum amplitude was better than that with no vibration.

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.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Green-State Micromilling of Additive Manufactured AISI316 L

2019 ◽  
Vol 7 (1) ◽  
Author(s):  
Sandeep Kuriakose ◽  
Paolo Parenti ◽  
Salvatore Cataldo ◽  
Massimiliano Annoni
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Defects ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Force Sensor ◽  
Depth Of Cut ◽  
Green State ◽  
Air Supply ◽  
Wide Range

Additive manufacturing (AM) of metal offers matchless design sovereignty to manufacture metallic microcomponents from a wide range of materials. Green-state micromilling is a promising method that can be integrated into the AM of metallic feedstock microcomponents in typical extrusion-based AM methods for compensating the inability to generate microfeatures. The integration enables the manufacturing of complex geometries, the generation of good surface quality, and can provide exceptional flexibility to new product shapes. This work is a micromachinability study of AISI316 L feedstock components produced by extrusion-based AM where the effects of workpiece temperature and the typical micromilling parameters such as cutting speed, feed per tooth, axial depth of cut, and air supply are studied. Edge integrity and surface roughness of the machined slots, as well as cutting forces, are analyzed using three-dimensional microscopy and piezoelectric force sensor, respectively. Green-state micromilling results were satisfying with good produced quality. The micromilling of heated workpieces (45 °C), with external air supply for debris removal, showed the best surface quality with surface roughness values that reached around Sa = 1.5 μm, much smaller than the average metal particles size. Minimum tendency to borders breakage was showed but in some cases microcutting was responsible of the generation of surface defects imputable to lack of adhesion of deposited layers. Despite this fact, the integrability of micromilling into extrusion-based AM cycles of metallic feedstock is confirmed.

Surface integrity in laser-assisted machining of Ti6Al4V

2020 ◽  
pp. 095440622097825
Author(s):  
O Kalantari ◽  
MM Fallah ◽  
F Jafarian ◽  
SR Hamzeloo
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Laser Source ◽  
Depth Of Cut ◽  
Thermal Source ◽  
Laser Assisted Machining

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

Investigation on surface quality of high-speed cutting titanium alloy Ti6Al4V based on Split-Hopkinson pressure bar

2020 ◽  
Vol 234 (10) ◽  
pp. 1293-1301 ◽  
Author(s):  
Zhanfei Zhang ◽  
Zengqiang Wang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Hopkinson Pressure Bar ◽  
High Speed Cutting ◽  
Pressure Bar

High-speed cutting technology has the characteristics of high material removal rate and excellent processing quality. To investigate the surface quality of high-speed cutting Ti6Al4V alloy, the orthogonal cutting experiment is the cutting device based on improved Split-Hopkinson pressure bar carried out with a cutting speed of about 7–16 m/s. Surface roughness, residual stress and three-dimensional surface topography are examined to characterize the surface quality. And the chip geometry parameters are measured to analyze the formation mechanism of surface topography. The result shows that cutting force and surface roughness increase rapidly with the increase in depth of cut. In the meantime, the periodic microwaves appeared on the machined surface, and their amplitudes increase with the increase in depth of cut. However, surface roughness, residual stress and microwave amplitude all decrease with the increase in cutting speed. Moreover, it is found that the evolution trend of chip thickness and surface roughness with cutting parameters is very similar. Therefore, it can be inferred that there is a strong relationship between surface topography and chip morphology.

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