scholarly journals Experimental and Simulation Study on Tool Life Models in Drilling of Forging Brass Using Uncoated-WC and AlCrN Coated-WC Tools

Coatings ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 853 ◽  
Author(s):  
Manit Timata ◽  
Charnnarong Saikaew
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Speed ◽  
Operating Costs ◽  
Data Sets ◽  
Burr Height ◽  
Life Values ◽  
Life Predictions ◽  
Exit Burr ◽  
Drilling Time

Burr is an undesirable phenomenon occurring in drilling operation which is one of the essential operations in the machining industry since it is directly influencing the operating costs. Exit burr height (EBH) values as the function of drilling time during drilling the specific holes of the forging brass workpieces used for producing the water-valve components with the uncoated- tungsten carbide (WC) and the AlCrN coated-WC drills were discussed. The data sets of drilling time, corresponding to EBH values at the appropriate criterion were used to develop the tool life models in terms of cutting speed and feed rate using Taylor’s equation. Monte Carlo simulation was adopted to study the uncertainty of cutting speed and feed rate on tool life predictions for sensitivity analysis. The results showed that drilling with a low feed rate decreased the averages of EBH. The predicted tool life values of the AlCrN coated-WC drills were higher than those of the uncoated-WC ones based on the results of tool life predictions. The appropriate operating condition of the cutting speed of 60 m/min and the feed rate of 0.2 mm/rev was recommended for manufacturers in the drilling of the forging brass workpieces using the AlCrN coated-WC drills. Moreover, the predicted tool life values for the uncoated-WC and the AlCrN coated-WC drills were about 600 and 800 min, respectively. This indicated that the AlCrN coated-WC drill increased tool life by 30%.

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.

Investigation of Ultrasonic-Assisted Drilling of Al/SiC Metal Matrix Composite with Taguchi Method

2012 ◽  
Vol 523-524 ◽  
pp. 215-219 ◽  
Author(s):  
Mohammad Ali Kadivar ◽  
Javad Akbari ◽  
Reza Yousefi
Keyword(s):  
Taguchi Method ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Burr Formation ◽  
Burr Height ◽  
Burr Size ◽  
Ultrasonic Assisted ◽  
Drilling Parameter ◽  
Sic Particle

Burr in drilling plays an important role on product quality, so analysis the burr size is essential at the final production. This paper presents the application of Taguchi method for survey the burr height and burr thickness by adding ultrasonic vibration to the process. In this paper L18 orthogonal array based on Taguchi techniques was used in the design of experiments. Analysis of Variance (ANOVA) was used to determination the effect of drilling parameter on burr formation. Influence of cutting speed, feed rate and percentage of SiC particle was investigated in with and without Ultrasonic assisted drilling. Al/SiCp MMC with 5, 15 and 20 wt% of particulate SiC in dry drilling operation with TiN coated drill tools were investigated.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

The Effect of Tool Edge Geometry on Tool Performance and Surface Integrity in Turning Ti-6Al-4V Alloys

2011 ◽  
Vol 264-265 ◽  
pp. 1211-1221 ◽  
Author(s):  
Yanuar Burhanuddin ◽  
Che Hassan Che Haron ◽  
Jaharah A. Ghani
Keyword(s):  
Tool Life ◽  
Surface Integrity ◽  
Feed Rate ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Edge Geometry ◽  
Tool Performance ◽  
Tool Edge ◽  
Structural Deformations ◽  
Notch Wear

This paper focuses on the influence of cutting tool edge geometry, cutting speed and feed rate on the tool performance and workpiece’s surface integrity in dry turning of Ti-6Al-4V alloy using PCBN inserts. The parameters evaluated are tool life, wear rate, wear mechanisms, surface roughness and subsurface microstructure alterations. The rate of wear growth of the insert was assessed by progressive flank wear using optical microscope by taking photographs after certain length of cut. The wear mechanism at the end of tool life was investigated in detail using scanning electron microscope (SEM) and EDAX analysis. The results show, by increasing the cutting speed and feed rate resulted in tool life reduction. Cutting with honed edge insert at cutting speed of 180 m/min has shown very little wear, even after 20 min of cutting. The honed insert proved less sensitive to increases in feed rate than the chamfered insert. In general the honed insert showed a significant improvement in tool life. All inserts failed due to attrition wear and adhesion. No flank notch wear was observed, but some crater wear occurred at the chamfer land. Microstructure alteration was not found when machining using the different edge geometry. In these trials, the subsurface micro structural deformations in the direction of cutting were deformed grain boundaries and elongation of grains. Chip smearing and debris on the surface was also found.

scholarly journals Drilling of Titanium/CFRP/Aluminium Stacks

2010 ◽  
Vol 447-448 ◽  
pp. 624-633 ◽  
Author(s):  
Islam Shyha ◽  
Sein Leung Soo ◽  
David K. Aspinwall ◽  
Sam Bradley ◽  
Stuart Dawson ◽  
...  
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Limiting Factor ◽  
Tool Coating ◽  
Cvd Diamond Coating ◽  
Torque Values ◽  
Coated Carbide ◽  
Multilayer Stacks

Following a review on the machinability of CFRP composites and multilayer stacks typically comprising metallic and composite material elements, the paper details experimental results when drilling 30 mm thick titanium/CFRP/aluminium workpiece stacks. Testing utilised a modified fractional factorial design based on an L18 Taguchi orthogonal array. This comprised four factors, three of which were at three levels and one at two levels and involved tool coating, cutting speed, feed rate and machining environment. Tools evaluated involved hardmetal and diamond coated carbide in addition to uncoated tungsten carbide drills. Response variables were principally tool wear and cutting force/torque with an end of test criteria of 300m flank wear. Peeling of the CVD diamond coating occurred within the first several holes drilled however this was not a limiting factor in terms of tool life. Principal damage occurred when drilling through the titanium (Ti-6Al-4V) rather than the aluminium (Al 7050) or CFRP (unidirectional “UD” laminates) sections. Best tool life/performance (310 drilled holes) was obtained with the more conventional uncoated carbide drills at lower cutting speed and feed rate. Typically thrust forces increased from 300 N for the first hole to ~2200 N for last hole drilled while torque values were generally below 600 N.cm for worn tools.

Influences of Spindle Speed and Feed Rate on Exit Burr Height and Workpiece Diameter in Drilling Forging Brass

2018 ◽  
Vol 279 ◽  
pp. 67-71 ◽  
Author(s):  
Manit Timata ◽  
Charnnarong Saikaew
Keyword(s):  
Experimental Design ◽  
Feed Rate ◽  
Spindle Speed ◽  
Experimental Investigations ◽  
Assembly Quality ◽  
Burr Height ◽  
Drilling Tools ◽  
Level Of Significance ◽  
Exit Burr ◽  
Operation Cost

Exit burrs are formed on the end of hole and have some undesirable characters leading to assembly quality problem. Deburring is one of the practical procedures used to solve this problem. Nevertheless, this step is a time consuming and causes high operation cost. This work studied the experimental investigations in drilling forging brass using a special tungsten carbide drilling tools. The exit burr height and workpiece diameter were measured at various spindle speeds and feed rates based on 2k plus center point experimental design and investigated by analysis of variance (ANOVA). The results of ANOVA indicated that spindle speed and feed rate on exit burr height and workpiece diameter were statistically significant at the level of significance of 0.05.

Multi-Objective Optimization Using Box-Behken of Response Surface Methodology for High-Speed Machining of Inconel 718

2014 ◽  
Vol 629 ◽  
pp. 487-492 ◽  
Author(s):  
Mohd Shahir Kasim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
E. Mohamad ◽  
Raja Izamshah ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling

This study was carried out to investigate how the high-speed milling of Inconel 718 using ball nose end mill could enhance the productivity and quality of the finish parts. The experimental work was carried out through Response Surface Methodology via Box-Behnken design. The effect of prominent milling parameters, namely cutting speed, feed rate, depth of cut (DOC), and width of cut (WOC) were studied to evaluate their effects on tool life, surface roughness and cutting force. In this study, the cutting speed, feed rate, DOC, and WOC were in the range of 100 - 140 m/min, 0.1 - 0.2 mm/tooth, 0.5 - 1.0 mm and 0.2 - 1.8 mm, respectively. In order to reduce the effect of heat generated during the high speed milling operation, minimum quantity lubrication of 50 ml/hr was used. The effect of input factors on the responds was identified by mean of ANOVA. The response of tool life, surface roughness and cutting force together with calculated material removal rate were then simultaneously optimized and further described by perturbation graph. Interaction between WOC with other factors was found to be the most dominating factor of all responds. The optimum cutting parameter which obtained the longest tool life of 60 mins, minimum surface roughness of 0.262 μm and resultant force of 221 N was at cutting speed of 100 m/min, feed rate of 0.15 mm/tooth, DOC 0.5 m and WOC 0.66 mm.

scholarly journals Estimation of tool life and cutting burr in high speed milling of the compacted graphite iron by DE based adaptive neuro-fuzzy inference system

2019 ◽  
Vol 10 (1) ◽  
pp. 243-254 ◽  
Author(s):  
Longhua Xu ◽  
Chuanzhen Huang ◽  
Rui Su ◽  
Hongtao Zhu ◽  
Hanlian Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
High Speed ◽  
Fuzzy Inference ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Compacted Graphite Iron ◽  
Inference System ◽  
Compacted Graphite ◽  
Neuro Fuzzy

Abstract. The studies of tool life and formation of cutting burrs in roughing machining field are core issues in high speed milling of compacted graphite iron (CGI). Changing any one of the cutting parameters like cutting speed or feed rate can result in varied tool life and different height of the cutting burrs. In this work in order to study the relationship between cutting parameters and tool life and height of the cutting burrs, a new differential evolution algorithm based on adaptive neuro fuzzy inference system (DE-ANFIS) as a multi-input and multi-output (MIMO) prediction model is introduced to estimate the tool life and height of the cutting burrs. In this model, the inputs are cutting speed, feed rate and exit angle, and the outputs are tool life and height of the cutting burrs. There are 12 fuzzy rules in DE-ANFIS architecture. Gaussian membership function is adopted during the training process of the DE-ANFIS. The proposed DE-ANFIS model has been compared with PSO-ANFIS, Artificial Neural Network (ANN) and Support Vector Machines (SVM) models. To construct the predictive models, 25 cutting data were obtained through the experiments. Compared with PSO-ANFIS, ANN and SVM models, the results indicate that DE-ANFIS can provide a better prediction accuracy of tool life and height of the cutting burrs, and achieve the required product and productivity. Finally, the analysis of variance (ANOVA) shows that the cutting speed and feed rate have the most effects on the tool life and height of cutting burrs, respectively.

scholarly journals Optimisation of Cutting Fluid Concentration and Operating Parameters based on RSM for Turning Ti–6Al–4V

2021 ◽  
Author(s):  
Salah Gariani ◽  
Mahmoud Elsayed ◽  
Islam Shyha
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Feed Rate ◽  
Linear Models ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Operating Parameters ◽  
Cutting Condition ◽  
Fluid Concentration

Abstract The paper details experimental and optimisation results for the effect of cutting fluid concentration and operating parameters on the average surface roughness (Ra) and tool flank wear (VB) when flooded turning of Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. Cutting fluid concentration, cutting speed, feed rate and cutting tool were the control variables. Response Surface Methodology (RSM) was employed to develop an experimental design and optimise Ra and VB using linear models. The study revealed that cutting fluid concentration has a little influence on Ra and VB performance while Ra was strongly affected by feed rate and cutting tool type. The developed empirical model also suggested that the best parameters setting to minimise Ra and VB are 5%, 58 m/min, 0.1 mm/rev for cutting fluid concentration, cutting speed and feed rate, respectively, using H13A tool. At this setting, the predicted surface roughness and tool wear were 0.48 and 30 µm, respectively. In the same vein, tool life and micro-hardness tests were performed at the suggested optimum cutting condition with different cutting speeds. A notable decrease in tool life (82.3%) was obtained when a higher cutting speed was used.

scholarly journals Step Over (ae) Effect on Cutting Parameters when Trochoidal Pocket Milling of Titanium Alloy Ti-6Al-4V

2019 ◽  
Vol 8 (6) ◽  
pp. 3419-3423
Keyword(s):  
Thermal Conductivity ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Feed Rate ◽  
Failure Modes ◽  
Cutting Speed ◽  
Weight Ratio ◽  
High Thermal Conductivity ◽  
Step Over

Titanium alloy is highly demanding in the aerospace industry due to its unique properties such are high strength-to-weight ratio and high thermal conductivity thus, made the material widely used in aerospace industries and excellent in its applications. However, those criteria’s become a crucial issue for machinists as titanium is categorized as difficult-to-machined material. High thermal conductivity caused shorten tool life because of the heat generated during machining was transferred directly to the cutting tool and leads to rapid tool wear. This experiment was conducted using 3 axis CNC Milling machine under wet cutting conditions. In order to identify the effect of step over, cutting speed and feed rate were fixed at constant values while step over (ae) values were varieties. The effect investigated were tool wear, wear mechanisms and tool failure modes. Tools experienced a longer tool life at low cutting speed of 60m/min, while chipping and notch wear appeared at high cutting speed 90m/min. The increasing of the step over value give less than 10% of the wear and reduced only 15% of machining time. With this, trochoidal milling proved that the step over give a minor contribution to wear while the dominant contribution was cutting speed followed by feed rate where the wear rate increased as the cutting speed increased.

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