Influence of cutting conditions of cast-metal cutting tools on their wear and durability: Analysis of cutting conditions of tools

2007 ◽  
Vol 28 (5) ◽  
pp. 416-421 ◽  
Author(s):  
A. S. Chaus ◽  
F. I. Rudnitskii
Keyword(s):  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
Cast Metal ◽  
Durability Analysis

On the Effects of a Built-Up Edge on Acoustic Emission in Metal Cutting

1990 ◽  
Vol 112 (2) ◽  
pp. 184-189 ◽  
Author(s):  
D. V. Hutton ◽  
Qinghuan Yu
Keyword(s):  
Acoustic Emission ◽  
Experimental Evidence ◽  
Deformation Zone ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Shear Angle ◽  
Cutting Conditions ◽  
Effective Rake Angle

Experimental evidence is presented which indicates that the presence of a built-up edge can significantly affect the generation of acoustic emission in metal cutting. Results for machining SAE 1018 and 4140 steels show that the built-up edge can mask the generally accepted AE-cutting speed relation when cutting tools having small rake angles are used. Under cutting conditions conducive to development of a built-up edge, it is shown that increased acoustic emission is generated as a result of increased effective rake angle and corresponding increase of shear angle in the primary deformation zone. Three distinct types of built-up edge have been observed and classified as immature, periodic, or developed, according to effect on acoustic emission.

scholarly journals Comparative tests of the metal cutting tools performance in the processing of stainless steels

2018 ◽  
Vol 441 ◽  
pp. 012052
Author(s):  
I V Shvetsov ◽  
B Ya Mokritskij ◽  
O A Malukhina ◽  
A H Rahmonov ◽  
V N Belyakov
Keyword(s):  
Stainless Steels ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Comparative Tests

Steady-State Thermal Stresses in Wedge-Shaped Cutting Tools

1975 ◽  
Vol 97 (3) ◽  
pp. 1060-1066
Author(s):  
P. F. Thomason
Keyword(s):  
Thermal Stress ◽  
Steady State ◽  
Metal Cutting ◽  
Thermal Stresses ◽  
Heat Conduction Problem ◽  
Equivalent Stress ◽  
Cutting Tools ◽  
Thermoelastic Stress ◽  
Plastic State ◽  
Steady State Heat

Closed form expressions for the steady-state thermal stresses in a π/2 wedge, subject to constant-temperature heat sources on the rake and flank contact segments, are obtained from a conformal mapping solution to the steady-state heat conduction problem. It is shown, following a theorem of Muskhelishvili, that the only nonzero thermal stress in the plane-strain wedge is that acting normal to the wedge plane. The thermal stress solutions are superimposed on a previously published isothermal cutting-load solution, to give the complete thermoelastic stress distribution at the wedge surfaces. The thermoelastic stresses are then used to determine the distribution of the equivalent stress, and this gives an indication of the regions on a cutting tool which are likely to be in the plastic state. The results are discussed in relation to the problems of flank wear and rakeface crater wear in metal cutting tools.

Hard Nano-Crystalline Coatings for Cutting Tools

2007 ◽  
Vol 567-568 ◽  
pp. 185-188 ◽  
Author(s):  
Miroslav Piska
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Dry Cutting ◽  
Nano Crystalline ◽  
The Right ◽  
Machining Productivity ◽  
Hard Cutting ◽  
Cutting Tool Materials

Modern trends in metal cutting, high speed/feed machining, dry cutting and hard cutting set more demanding characteristics for cutting tool materials. The exposed parts of the cutting edges must be protected against the severe loading conditions and wear. The most significant coatings methods for cutting tools are PVD and CVD/MTCVD today. The choice of the right substrate or the right protective coating in the specific machining operation can have serious impact on machining productivity and economy. In many cases the deposition of the cutting tool with a hard coating increases considerably its cutting performance and tool life. The coating protects the tool against abrasion, adhesion, diffusion, formation of comb cracks and other wear phenomena.

Nanostructural wear-resistant coatings produced on metal-cutting tools by electric-arc evaporation and magnetronic sputtering

2010 ◽  
Vol 30 (9) ◽  
pp. 910-920 ◽  
Author(s):  
F. V. Kiryukhantsev-Korneev ◽  
N. A. Shirmanov ◽  
A. N. Sheveiko ◽  
E. A. Levashov ◽  
M. I. Petrzhik ◽  
...  
Keyword(s):  
Metal Cutting ◽  
Cutting Tools ◽  
Electric Arc ◽  
Wear Resistant ◽  
Wear Resistant Coatings ◽  
Arc Evaporation

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

Experimental Study on Tool Wear when Machining Super Titanium Alloys: Ti6Al4V and Ti-555

2013 ◽  
Vol 763 ◽  
pp. 51-64
Author(s):  
Mohammed Nouari ◽  
Hamid Makich
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Wear Behavior ◽  
Flow Direction ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Wear Process ◽  
Texture Modification ◽  
Wear Modes

To understand the effect of the workpiece microstructure on the tool wear behavior, anexperimental investigation was conducted on machining two different microstructures of supertitanium alloys: Ti-6Al-4V and Ti-555. The analysis of tool-chip interface parameters such asfriction, heat flux and temperature rise and the evolution of the workpiece microstructure underdifferent cutting conditions have been discussed. As cutting speed and feed rate increase, the meancutting forces and temperature show different progressions depending on the consideredmicrostructure. Results show that wear modes for cutting tools used in machining the Ti-555 alloyshow contrast from those exhibited by tools used in machining the Ti6AI4V alloy. In fact, onlyabrasion wear was observed for cutting tools in the case of machining the near-β titanium Ti-555alloy. The last alloy is characterized by a fine-sized microstructure (order of 1 μm). For the usualTi6Al4V alloy, adhesion and diffusion modes followed by coating delamination process on the toolsubstrate have been clearly identified. Moreover, a deformed layer was observed under secondaryelectron microscope (SEM) from the sub-surface of the chip with β-grains orientation along thechip flow direction. The analysis of the microstructure confirms the intense deformation of themachined surface and shows a texture modification, without phase transformation. For the Ti-555β-alloy, β grains experiences more plastic deformation and increases the microhardness of theworkpiece inducing then an abrasion wear process for cemented carbide tools. For the Ti6Al4Vmicrostructure, the temperature rise induces a thermal softening process of the workpiece andgenerates adhesive wear modes for cutting tools. The observed worn tool surfaces confirm theeffect of the microstructure on tool wear under different cutting conditions for the two studiedtitanium alloys.

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