CUTTING TOOL PERFORMANCE IN TURNING  OF AL 7075-T651 ALUMINIUM ALLOY

Recently, almost 70% of a commercial jetliner’s airframe is made of aluminium alloys. It is predicted that the application of aluminium alloy is to increase up to 65% by the year 2025. They are typically used because of their high strength to weight ratio. However, there are some drawbacks during machining aluminium alloy such as the adhesion wear and built-up edge (BUE) formation that can shorten tool life. As the tool wears, the machining performance, surface roughness, and cutting tool life are affected significantly. A lot of studies were conducted in order to minimize this critical issue. This project presents a study of the cutting tool performance of an uncoated carbide tool in dry turning operation on Al 7075-T651, in which the tool wear rate, volume of material removed, wear mechanism, and surface roughness were investigated. The machining tests were conducted on a CNC lathe machine to obtain the tool wear and surface roughness of the machined work piece. The average flank wear was measured using a digital microscope, whereas the wear mechanism was observed using a Scanning Electron Microscope (SEM). The average surface roughness (Ra) was measured using a surface roughness tester. The cutting time for this experiment was fixed at 40 minutes and all the results were analysed within this time range to evaluate the tool performance in the turning of Al 7075-T651. The results revealed that the tool performs better at low cutting speed, 250 m/min, by reducing the tool wear rate by 33%. The cutting speed of 250 m/min also contributed to 71% higher volume of material removed during the machining tests. The dominant type of wear found was flank wear, while the main principal of wear mechanism is adhesion. At higher cutting speed, the surface roughness was improved. Based on the results, it can be concluded that high cutting tool performance is achieved when low tool wear growth rate, high volume of material removal, and low surface roughness during turning operation are obtained. ABSTRAK: Kebelakangan ini, hampir 70% kerangka pesawat udara komersil diperbuat daripada aloi aluminium. Penggunaan aloi aluminum ini dijangka meningkat sehingga 65% pada tahun 2025. Ia biasa digunakan kerana nisbah kekuatan kepada berat yang tinggi. Walau bagaimanapun, terdapat beberapa kekurangan semasa pemesinan aloi aluminum ini iaitu pemakaian pelekat dan pembentukan binaan tepi (BUE) yang mengurangkan jangka hayat mata alat. Apabila mata alat menjadi haus, prestasi mesin, kekasaran permukaan, dan jangka hayat mata alat pemotong terjejas dengan ketara. Banyak kajian telah dijalankan bagi mengurangkan isu kritikal ini. Projek ini mengkaji prestasi mata alat pemotong karbida tidak bersalut dalam operasi mesin larik kering pada Al 7075-T651, di mana kadar haus mata alat, kuantiti bahan yang dibuang, mekanisme haus dan kekasaran permukaan telah diselidiki. Ujian pemesinan dijalankan pada mesin CNC mesin larik bagi mendapatkan kadar haus mata alat dan kekasaran permukaan material yang dimesin. Purata haus pengapit mata alat diukur dengan menggunakan mikroskop digital, manakala mekanisme haus dipantau menggunakan Mikroskop Elektronik Pengimbas (SEM). Purata kekasaran permukaan (Ra) diukur menggunakan alat penguji kekasaran permukaan. Tempoh masa pemotongan bagi eksperimen ini telah ditetapkan pada 40 minit dan semua keputusan telah dianalisa dalam tempoh masa ini bagi menilai prestasi mata alat dalam melarik Al 7075-T651. Hasil menunjukkan prestasi mata alat lebih baik pada kelajuan pemotongan rendah, 250 m/min dengan mengurangkan kadar haus mata alat sehingga 33%. Kelajuan pemotongan 250 m/min juga menyumbang kepada 71% peningkatan ke atas jumlah bahan yang dibuang semasa ujian pemesinan. Jenis haus yang dominan telah ditemui pada pengapit mata alat, manakala mekanisme haus yang utama adalah lekatan. Pada kelajuan pemotongan yang tinggi, kekasaran permukaan didapati lebih baik. Berdasarkan keputusan, dapat disimpulkan bahawa prestasi mata alat pemotong yang bagus dapat dicapai apabila kadar haus mata alat adalah rendah, jumlah penyingkiran bahan yang tinggi dan kekasaran permukaan yang rendah semasa operasi pelarikan dijalankan. ABSTRAK: Kebelakangan ini, hampir 70% kerangka pesawat udara komersil diperbuat daripada aloi aluminium. Penggunaan aloi aluminum ini dijangka meningkat sehingga 65% pada tahun 2025. Ia biasa digunakan kerana nisbah kekuatan kepada berat yang tinggi. Walau bagaimanapun, terdapat beberapa kekurangan semasa pemesinan aloi aluminum ini iaitu pemakaian pelekat dan pembentukan binaan tepi (BUE) yang mengurangkan jangka hayat mata alat. Apabila mata alat menjadi haus, prestasi mesin, kekasaran permukaan, dan jangka hayat mata alat pemotong terjejas dengan ketara. Banyak kajian telah dijalankan bagi mengurangkan isu kritikal ini. Projek ini mengkaji prestasi mata alat pemotong karbida tidak bersalut dalam operasi mesin larik kering pada Al 7075-T651, di mana kadar haus mata alat, kuantiti bahan yang dibuang, mekanisme haus dan kekasaran permukaan telah diselidiki. Ujian pemesinan dijalankan pada mesin CNC mesin larik bagi mendapatkan kadar haus mata alat dan kekasaran permukaan material yang dimesin. Purata haus pengapit mata alat diukur dengan menggunakan mikroskop digital, manakala mekanisme haus dipantau menggunakan Mikroskop Elektronik Pengimbas (SEM). Purata kekasaran permukaan (Ra) diukur menggunakan alat penguji kekasaran permukaan. Tempoh masa pemotongan bagi eksperimen ini telah ditetapkan pada 40 minit dan semua keputusan telah dianalisa dalam tempoh masa ini bagi menilai prestasi mata alat dalam melarik Al 7075-T651. Hasil menunjukkan prestasi mata alat lebih baik pada kelajuan pemotongan rendah, 250 m/min dengan mengurangkan kadar haus mata alat sehingga 33%. Kelajuan pemotongan 250 m/min juga menyumbang kepada 71% peningkatan ke atas jumlah bahan yang dibuang semasa ujian pemesinan. Jenis haus yang dominan telah ditemui pada pengapit mata alat, manakala mekanisme haus yang utama adalah lekatan. Pada kelajuan pemotongan yang tinggi, kekasaran permukaan didapati lebih baik. Berdasarkan keputusan, dapat disimpulkan bahawa prestasi mata alat pemotong yang bagus dapat dicapai apabila kadar haus mata alat adalah rendah, jumlah penyingkiran bahan yang tinggi dan kekasaran permukaan yang rendah semasa operasi pelarikan dijalankan.

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Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

10.21203/rs.3.rs-362139/v1 ◽

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.

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Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

Advances in Materials Science and Engineering ◽

10.1155/2019/5868132 ◽

2019 ◽

Vol 2019 ◽

pp. 1-10 ◽

Cited By ~ 5

Author(s):

Harun Gokce

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Tool Wear ◽

Taguchi Method ◽

Cutting Tool ◽

Cutting Tools ◽

Cutting Speed ◽

Cutting Parameters ◽

Cutting Tool Wear ◽

Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

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

10.21203/rs.3.rs-956224/v1 ◽

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.

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Influence of Cutting Parameters and Tool Wear on Martensitic Stainless Steel Surface Integrity After a Face Milling Process

Volume 6: Materials and Fabrication, Parts A and B ◽

10.1115/pvp2009-77024 ◽

2009 ◽

Cited By ~ 2

Author(s):

Patricia Mun˜oz de Escalona ◽

Paul G. Maropoulos

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Tool Wear ◽

Surface Integrity ◽

Surface Finish ◽

Cutting Tool ◽

Fatigue Behavior ◽

Cutting Speed ◽

Stainless Steel Surface ◽

Workpiece Material

Surface finish is one of the most relevant aspects of machining operations, since it is one of the principle methods to assess quality. Also, surface finish influences mechanical properties such as fatigue behavior, wear, corrosion, etc. The feed, the cutting speed, the cutting tool material, the workpiece material and the cutting tool wear are some of the most important factors that affects the surface roughness of the machined surface. Due to the importance of the martensitic 416 stainless steel in the petroleum industry, especially in valve parts and pump shafts, this material was selected to study the influence of the feed per tooth and cutting speed on tool wear and surface integrity. Also the influence of tool wear on surface roughness is analyzed. Results showed that high values of roughness are obtained when using low cutting speed and feed per tooth and by using these conditions tool wear decreases prolonging tool life.

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Research on the Wear Process of High Speed Cutting Ni-Based Superalloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.102 ◽

2014 ◽

Vol 800-801 ◽

pp. 102-106

Author(s):

Jun Zhou ◽

Ming Pu Liu ◽

Hong Qi Sun

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Cutting Force ◽

Wear Mechanism ◽

High Speed ◽

Cutting Tool ◽

Cutting Temperature ◽

Wear Process ◽

High Speed Cutting ◽

Cutting Tool Wear

As the main method of high efficiency cutting Ni-based superalloy, high-speed cutting can not but intensify the cutting-tool wear for the high cutting force and cutting temperature. So, it is very necessary to study the process of cutting-tool wear and wear mechanism, especially, the effect of cutting-tool wear on the cutting force, cutting temperature and surface roughness of machined workpiece. In this paper, investigation of tool wear in high-speed cutting is proposed, the PCDTiAlN carbide insert is used in the experiment, the cutting-tool wear and the corresponding cutting force, cutting temperature and surface roughness of machined workpiece is detected. It indicates that the cutting force, cutting temperature and surface roughness of machined workpiece is changed corresponding the cutting-tool wear,the wear process of coated tool include the coated material wears and base material wears,the wear mechanism is complex. Key word: superalloy, high-speed cutting, tool wear, wear form ; .

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Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

Journal of Metallurgy ◽

10.1155/2016/7407918 ◽

2016 ◽

Vol 2016 ◽

pp. 1-10 ◽

Cited By ~ 8

Author(s):

Manikandakumar Shunmugavel ◽

Ashwin Polishetty ◽

Junior Nomani ◽

Moshe Goldberg ◽

Guy Littlefair

Keyword(s):

Tool Wear ◽

Cutting Tool ◽

Flank Wear ◽

Research Work ◽

Cutting Speed ◽

Machined Surface ◽

Machined Surface Quality ◽

Coating Delamination ◽

All Speeds ◽

Cutting Speeds

This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

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Optimization of Machining Parameters on 7075 Aluminum Alloy using Taguchi and ANOVA for Surface Roughness

International Journal of Recent Technology and Engineering - 2 ◽

10.35940/ijrte.c6170.018520 ◽

2020 ◽

Vol 8 (5) ◽

pp. 90-95

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Electrical Discharge Machining ◽

Optimization Technique ◽

Cutting Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

Anova Analysis ◽

Tool Wear Rate ◽

Made In

Optimization of the parameter to provide best solution to reduce the tool wear , surface roughness, cutting forces presented using optimization technique .In present work an experimental study is made. In this Taguchi design of experiment methodology for optimization of parameters on 7075Aluminium alloy using tungsten coated electrode . Experiments were conducted based on L27 standard orthogonal array with three processes parameters are cutting speed, feed, depth of cut . Electrical discharge machining is generally calculated on the basis of Surface Roughness (SR),Tool wear rate (TWR) and cutting force (CF) .The ANOVA(Analysis Of Variance) is used to study the performance characteristics in turning operation . ANOVA placed an important role for producing higher roughness . Finally the software ,MINITAB 17 was used and results obtained

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

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686717500159 ◽

2017 ◽

Vol 16 (03) ◽

pp. 237-261 ◽

Cited By ~ 3

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.

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Experimental Analysis Of Coated And Uncoated Twist Drill; Review

International Journal of Mechanical and Industrial Engineering ◽

10.47893/ijmie.2011.1006 ◽

2011 ◽

pp. 22-25

Author(s):

S. S. Pathak ◽

V. R Kagade ◽

M. S. Kadam

Keyword(s):

Neural Network ◽

Surface Roughness ◽

Tool Wear ◽

Cutting Tool ◽

Back Propagation ◽

Cutting Speed ◽

Back Propagation Neural Network ◽

Tool Selection ◽

Radial Basis Neural Network ◽

Different Types

Drilling is a process of making hole in a solid body with the help of multipoint cutting tool. Here to improve the life of tool, in order to minimize the production cost, to increase surface roughness different types of coating are applying over it, that coating soft/hard/ soft+ hard. Tool selection depends upon nature of drilling; dry, with coolant. This paper gives review of different coating techniques and its effectiveness by measuring deviation in hole diameter, surface roughness, and wear measurement. A back propagation neural network is preferred instead of radial basis neural network for the prediction of tool wear. It is considered that tool wear depends on cutting speed, feed, thrust force and torque.

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