Study The Effect of Cutting Conditions (Cutting Speed, Depth of Cut, Feed ) on The Wear of Cutting Tool Bit Turning Machine

2013 ◽  
Vol 1 (2) ◽  
pp. 44-55
Author(s):  
Niema H Elmosawi ◽  
Shalan Gannam Al ◽  
Hamid H. Ali
Keyword(s):  
High Temperature ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Wear Test ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Test Results

The aim of the work is to study the effect of cutting condition on cutting bit of the turning machine while working on different metal ,Through using a special type of commonly used cutting tool bit in (HSS) due to the high qualifications it is characterized by cutting ,and its endurance of high temperature .Two types of metal are used in cutting (Aluminum, Mild steel),relying on the working conditions used in the machine(feed, cutting speed، depth of cut),while conducting working processes via using cooling liquid ,and without it .The wear test results shown that there are two types of wear measured by the (tool micker microscope) :Flank wear and Greater wear, are formed on the cutting edge of the tool bits as a result of the great effect of cutting conditions on the tool bit and the high temperature of the chips ;in addition to the occurrence of resulting edge on the cutting edge of the tool bits in the process of cutting aluminum , with the use of cooling liquids which prolong the of cutting tool and decrease the periods of re-grinding the cutting tool bit. 

Life Prediction of Cutting Tool by the Workpiece Cutting Condition

2011 ◽  
Vol 223 ◽  
pp. 554-563 ◽  
Author(s):  
Noemia Gomes de Mattos de Mesquita ◽  
José Eduardo Ferreira de Oliveira ◽  
Arimatea Quaresma Ferraz
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Operating Conditions ◽  
Production Costs ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Workpiece Material ◽  
The Cost

Stops to exchange cutting tool, to set up again the tool in a turning operation with CNC or to measure the workpiece dimensions have direct influence on production. The premature removal of the cutting tool results in high cost of machining, since the parcel relating to the cost of the cutting tool increases. On the other hand the late exchange of cutting tool also increases the cost of production because getting parts out of the preset tolerances may require rework for its use, when it does not cause bigger problems such as breaking of cutting tools or the loss of the part. Therefore, the right time to exchange the tool should be well defined when wanted to minimize production costs. When the flank wear is the limiting tool life, the time predetermination that a cutting tool must be used for the machining occurs within the limits of tolerance can be done without difficulty. This paper aims to show how the life of the cutting tool can be calculated taking into account the cutting parameters (cutting speed, feed and depth of cut), workpiece material, power of the machine, the dimensional tolerance of the part, the finishing surface, the geometry of the cutting tool and operating conditions of the machine tool, once known the parameters of Taylor algebraic structure. These parameters were raised for the ABNT 1038 steel machined with cutting tools of hard metal.

Machining characteristics of Inconel 718 under several cutting conditions based on Taguchi method

2012 ◽  
Vol 227 (9) ◽  
pp. 1889-1897 ◽  
Author(s):  
R Thirumalai ◽  
JS Senthilkumaar ◽  
P Selvarani ◽  
S Ramesh
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Flank Wear ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Parameters ◽  
Dry Machining ◽  
Noise Factors

Extensive researchers have conducted several experiments in the past for selecting the optimum parameters in machining nickel based alloy – Inconel 718. These experiments conducted so far are dealt with dry machining and flooded coolant machining of nickel alloy Inconel 718. In this research study, the usage of refrigerated coolant is also dealt with and it is compared with dry machining and flooded coolant machining. Cutting speed, feed and depth of cut are considered as the machining parameters. The effectiveness of the refrigerated coolant in machining the heat resistant super alloy material Inconel 718 with respect to these machining parameters are described in this article. The machinability studies parameters were generated with surface roughness and flank wear. The performance of uncoated carbide cutting tool was investigated at various cutting condition under dry, flooded coolant and refrigerated coolant machining. The relationship between the machining parameters and the performance measures were established and using analysis of variance significant machining parameters determined. This article made an attempt to Taguchi optimization technique to study the machinability performances of Inconel 718. Taguchi approach is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer experiments than a factorial design. Taguchi’s optimization analysis indicates that the factors level, its significance to influence the surface roughness and flank wear for the machining processes. Confirmation tests were conducted at an optimal condition to make a comparison between the experimental results foreseen from the mentioned correlations.

scholarly journals Performance of Near Dry Hard Machining Through Pressurised Air Water Mixture Spray Impingement Cooling Environment

2019 ◽  
Vol 16 (1) ◽  
pp. 6108-6133
Author(s):  
R. Kumar ◽  
A.K. Sahoo ◽  
P.C. Mishra ◽  
R.K. Das
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Water Mixture ◽  
Impingement Cooling ◽  
Aisi D2 ◽  
Spray Impingement

The present paper emphasizes on experimental investigation, mathematical modelling, optimisation, tool life and cost analysis during machining of AISI D2 (heat treated) (55±1 HRC) steel using uncoated carbide tool through a novel method under spray impingement cooling environment. Taguchi based L16 orthogonal array was utilised to conduct the experiments. Analysis of variance with 95% confidence level shows that the feed and depth of cut, are the most compelling factor towards surface roughness as well as chip reduction coefficient whereas cutting speed is the utmost compelling feature associated to flank wear as well as chip-tool interface temperature. Optimised result is identified as v1-f1-d1 (machining speed of 63 m/min; cutting feed of 0.04 mm/rev and depth of cut of 0.1 mm) based on grey relational analysis and tool life is found to be 15 minutes at optimised cutting conditions. Flank wear due to abrasion, catastrophic failure due to diffusion, chipping and notch wear are noticed as the major tool wear mechanisms in hard turning. Mathematical machinability models show statistically significance because due to the superior coefficient of correlations. As the global machining cost for each part is less, uncoated carbide tools can machine effectively, efficiently and economically at optimum cutting conditions under spray environment.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Wear Mechanism of Ti(C, N)-Based Cermet Cutting Tools in the Machining of Normalized Medium Carbon Steel AISI1045

2007 ◽  
Vol 353-358 ◽  
pp. 792-795 ◽  
Author(s):  
Zeng Min Shi ◽  
Yong Zheng ◽  
Wen Jun Liu
Keyword(s):  
Carbon Steel ◽  
Wear Mechanism ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Vacuum Sintering ◽  
Medium Carbon

Ti(C, N)-based cermet cutting tools were prepared by vacuum sintering and tested in dry machining of normalized medium carbon steel (AISI1045) at various combinations of cutting speed (Vc), feed rate (f), and depth of cut (ap). And the wear mechanism was investigated in detail using scanning electron microscopy (SEM) and electron-probe microanalysis (EPMA). Comparing to the cemented carbide YT15 and cermet TN20, the newly fabricated cermet tools exhibited better performance and higher wear resistance. For Ti(C, N)-based cermet tools, the wear mechanism was predominantly controlled by the flank wear under all cutting condition. It was found that the removal of the ceramic grain and abrasive wear were the main source of tools failure. In addition, adhesion and oxidation were also observed.

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

2017 ◽  
Vol 16 (03) ◽  
pp. 237-261 ◽  
Author(s):  
T. Sampath Kumar ◽  
S. Balasivanandha Prabu ◽  
T. Sorna Kumar
Keyword(s):  
Surface Roughness ◽  
Alloy Steel ◽  
Surface Finish ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Coated Carbide

In the present work, the performances of TiAlN-, AlCrN- and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN- and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi’s approach is used to obtain the best turning parameters, namely cutting speed ([Formula: see text]), feed rate ([Formula: see text]) and depth of cut ([Formula: see text]), in order to have a better surface finish and minimum tool flank wear. An orthogonal array (L[Formula: see text] was used to conduct the experiments. The results show that the AlCrN/TiAlN-coated cutting tool provided a much better surface finish and minimum tool flank wear. The minimum tool flank wear and minimum surface roughness were obtained using AlCrN/TiAlN-coated tools, when [Formula: see text][Formula: see text]m/min, [Formula: see text][Formula: see text]mm/rev and [Formula: see text][Formula: see text]mm.

Experimental Characterization of Laser-Assisted Mechanical Micromachining (LAMM) Process

2005 ◽  
Author(s):  
Ramesh Singh ◽  
Shreyes N. Melkote
Keyword(s):  
Laser Power ◽  
Cutting Tool ◽  
Continuous Wave ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Hard Material ◽  
Experimental Characterization ◽  
Mechanical Micromachining

There is growing demand for micro and meso scale devices in the field of optics, semiconductors and bio-medical devices. In response to this demand, mechanical micro-cutting (e.g. micro-turning, micro-milling) is emerging as a viable alternative to lithography based micromachining techniques. However, certain factors limit the types of workpiece materials that can be processed using mechanical micromachining methods. For difficult-to-machine materials such as mold and die steels, limitations in cutting tool stiffness and strength are major impediments to the use of mechanical micromachining methods. This paper presents a Laser Assisted Mechanical Micromachining (LAMM) process that involves highly localized thermal softening of the hard material by focusing a solid-state continuous wave/pulsed laser beam in front of a miniature (100μm–1mm wide) cutting tool. By suitably controlling the laser power, location and spot size, it is possible to cause a sufficiently large decrease in the strength of the work material and thereby minimize catastrophic tool failure and lower tool forces and deflection. This paper presents the results of experimental characterization of the LAMM process. Micro scale grooving experiments are conducted on H-13 mold steel (42 HRc) in order to understand the influence of the laser variables (laser power, beam location with respect to tool) and cutting parameters (depth of cut, cutting speed and tool width) on the cutting forces and surface finish. The results show that, for a given cutting condition, these process responses are significantly influenced by the laser variables. Plausible explanations for the observed trends are given.

Effect of Microwave Sintering Treatment to the Flank Wear of Titanium Carbide Tools in Milling Operations

2015 ◽  
Vol 1115 ◽  
pp. 59-63
Author(s):  
Mohammad Iqbal ◽  
Tasnim Firdaus Ariff ◽  
Mohd Shahrul Fahmi bin Mat Roseh ◽  
Muataz Hazza Faizi Al-Hazza ◽  
Irfan Hilmy ◽  
...  
Keyword(s):  
Titanium Carbide ◽  
Cutting Tool ◽  
Flank Wear ◽  
Microwave Sintering ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Constant Depth ◽  
Machining Time ◽  
Milling Operations ◽  
The Face

The paper reports the research on the improvement of tool wear resistant of Titanium Carbide (TiC) cutting tool after microwave post sintering treatment. Titanium Carbide square milling insert was microwave sintered at 600°C with 15 minutes of holding time. The face milling operations were conducted to Carbon Steel S45C block (130 mm x 95 mm x 40 mm) by using both of original and microwave sintered insert at 5 different cutting speed (60, 90 , 120 , 150 and 180 m/min), constant feed rate (0.2 mm/tooth) and constant depth of cut (0.2 mm/tooth). The flank wear of the insert was measured every nearest 10th minute of complete cutting passes. The results of the experiment show that microwave post sintering treatment improves the tool resistant of the TiC insert. The flank wear of the sintered insert is lower at any machining time and all cutting speed. The research also found that the percentage of the improvement is lower at higher cutting speed compare to lower cutting speed.

scholarly journals Optimizing Multi-Response Parameters in Turning of AISI1040 Steel Using Desirability Approach

2019 ◽  
Vol 4 (4) ◽  
pp. 905-921
Author(s):  
Srinu Gugulothu ◽  
Vamsi Krishna Pasam
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Multi Objective ◽  
Single Objective

In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.

Optimization of Surface Roughness in Dry Turning of Brass

2013 ◽  
Vol 395-396 ◽  
pp. 1035-1039
Author(s):  
On Uma Lasunon
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Arithmetic Mean ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Average Surface Roughness ◽  
Dry Turning ◽  
Carbide Cutting Tool ◽  
Optimal Cutting Condition

This study aimed to investigate the effect of cutting speed, feed and depth of cut on the arithmetic mean surface roughness (Ra). The optimal cutting condition in dry turning brass with carbide cutting tool was also recommended. The experimentation was designed by using Taguchi Method (L9). Three investigated factors with 3-level each were cutting speed (42, 68 and 110 m/min), feed (0.05, 0.1 and 0.15 mm/rev), and depth of cut (0.15, 0.25 and 0.5 mm). The results indicated that speed and feed were significantly affected at average surface roughness. The optimal cutting conditions were cutting speed at 68 m/min, feed at 0.05 mm/rev and depth of cut at 0.15 mm.

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