scholarly journals Machining of Iron-Carbon Alloys by the Use of Poly-Crystalline Diamond Cutting Inserts with Internal Cooling

2018 ◽  
Vol 2 (3) ◽  
pp. 57 ◽  
Author(s):  
Manuel Reiter ◽  
Jens Brier ◽  
Friedrich Bleicher
Keyword(s):  
Wear Behavior ◽  
Cutting Tools ◽  
Tool Material ◽  
Internal Cooling ◽  
Diamond Cutting ◽  
Diffusion Effects ◽  
Cutting Inserts ◽  
Abrasive Cutting ◽  
Poly Crystalline Diamond ◽  
Insight Into

Poly-crystalline diamond (PCD) is an extremely tough, synthetically produced cutting tool material, which offers outstanding capabilities concerning wear behavior in abrasive cutting environments. Currently, the primary application of PCD cutting tools is the machining of non-ferrous materials, as the diamond’s carbon high affinity towards iron causes diffusion effects while cutting steel with rising temperature. This effect significantly reduces tool life. To lower the occurring temperature of the cutting process, and therefore avoid the reaction of carbon and iron, a thermal functionalization of the cutting inserts has been investigated. The results give insight into making PCD cutting tools economically usable for the machining of iron-carbon materials.

Wear Mechanisms of Multi-Layer Coated Cemented Carbide Cutting Tools

1997 ◽  
Vol 119 (1) ◽  
pp. 8-17 ◽  
Author(s):  
S.-S. Cho ◽  
K. Komvopoulos
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Tool Material ◽  
Surface Plastic ◽  
Delamination Wear ◽  
Interfacial Cracks ◽  
Plastic Shearing ◽  
Coated Cemented Carbide

Turning experiments were performed with cemented WC-Co cutting tools coated with two-layer and three-layer overcoats of TiC/Al2O3 and TiC/Al2O3/TiN, respectively. For comparison, uncoated WC-Co tools were also tested under similar cutting conditions. The predominant wear mechanisms of the various ceramic overcoats and cemented WC-Co were investigated using surface profilometry, scanning electron microscopy, and energy dispersive X-ray analysis. Representative results of the tool wear behavior are presented, and the significance of each ceramic layer on the overall tool wear resistance is interpreted in light of the identified dominant wear mechanisms. Delamination wear characterized by the propagation and linkage of surface, subsurface, and interfacial cracks, abrasion, surface plastic shearing, plucking of carbide grains, and dissolution/diffusion are shown to occur depending on the tool material. These wear processes are not mutually exclusive; they may occur simultaneously at different positions on the same tool surface. Based on nose wear data, correlations between wear lives of coated and uncoated tools and feedrate are established.

An Investigation on Machining Behaviour of Metal Matrix Composites by Using PCD Inserts

2005 ◽  
Author(s):  
N. Muthu Krishnan ◽  
D. Vikram ◽  
S. Kaushik ◽  
K. Prahalada Rao
Keyword(s):  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Wear Behavior ◽  
Removal Rate ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Worn Surface ◽  
Poly Crystalline Diamond

The present work has been undertaken to study the tool wear behavior of poly crystalline diamond (PCD) inserts during the machining of Al-SiC – MMC; Al-Si alloy containing 15%wt of SiC was used for machining and PCD inserts of three different grades were used as cutting tools. The main aim of this paper is to explore the feasibility of machining conditions by setting the spindle speed, depth of cut and thereby determining the cutting force, surface roughness, power consumed, material removal rate and tool wear. The worn surface of the insert was examined by Scanning electron microscope (SEM). The influence of cut was examined for the PCD inserts.

Thermodynamic, Tribological and Chemical Interdiffusion Study of Ultra-Hard Ceramic AlMgB14 in the Machining of Aerospace Alloys

Manufacturing ◽  
2003 ◽  
Author(s):  
Vikram Bedekar ◽  
Deepak G. Bhat ◽  
Stephen A. Batzer ◽  
Larry Walker ◽  
L. F. Allard
Keyword(s):  
Titanium Alloys ◽  
Cutting Tool ◽  
Wear Behavior ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Tool Material ◽  
Work Piece ◽  
Tool Materials ◽  
Aerospace Alloys ◽  
Cutting Tool Materials

There has been a growing concern about the reactivity at the tool/work-piece interface during machining, leading to lower tool life. The problem is more severe especially in the case of aerospace alloys such as Ti-6Al-4V and stainless steels. Recently, a new ultra hard ceramic material, AlMgB14, was reported with properties that show considerable promise as a cutting tool material for machining titanium alloys [1]. This paper investigates the chemical wear behavior of AlMgB14, in the machining of aerospace alloys. The mechanical properties of AlMgB14 are compared with leading cutting tool materials (WC-Co, Al2O3SiCw-TiC and Al2O3-TiC), which are used extensively in machining titanium and ferrous alloys. Materials characterization of candidate tool materials shows that AlMgB14 exhibits superior hardness, fracture toughness and abrasive wear resistance as compared to the other cutting tool materials. We also report on a study of chemical reactivity of tool materials (AlMgB14 and WC-6%Co) in machining various alloys such as Ti-6Al-4V and Fe-18Ni-8Cr. The chemical reactivity was investigated using diffusion tests conducted in vacuum at 1000°C for 120 hrs. Transverse sections of couples were characterized using electron probe micro analysis (EPMA), to determine the extent of diffusion zones. The results show that AlMgB14 shows considerably less reactivity with titanium alloys when compared with cemented carbide cutting tools. It was also observed that the boride reacts significantly with the iron based Fe-18Ni-8Cr alloy. The paper also reports on the evaluation of the free energy of formation of AlMgB14 using the thermochemical software program FactSage™.

scholarly journals Feasibility of Cobalt-Free Nanostructured WC Cutting Inserts for Machining of a TiC/Fe Composite

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3432
Author(s):  
Edwin Gevorkyan ◽  
Mirosław Rucki ◽  
Tadeusz Sałaciński ◽  
Zbigniew Siemiątkowski ◽  
Volodymyr Nerubatskyi ◽  
...  
Keyword(s):  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Machined Surface ◽  
Powder Consolidation ◽  
Plasma Sintering ◽  
Cutting Inserts ◽  
Spark Plasma ◽  
And Performance ◽  
Nanostructured Tungsten Carbide

The paper presents results of investigations on the binderless nanostructured tungsten carbide (WC) cutting tools fabrication and performance. The scientific novelty includes the description of some regularities of the powder consolidation under electric current and the subsequent possibility to utilize them for practical use in the fabrication of cutting tools. The sintering process of WC nanopowder was performed with the electroconsolidation method, which is a modification of spark plasma sintering (SPS). Its advantages include low temperatures and short sintering time which allows retaining nanosize grains of ca. 70 nm, close to the original particle size of the starting powder. In respect to the application of the cutting tools, pure WC nanostructure resulted in a smaller cutting edge radius providing a higher quality of TiC/Fe machined surface. In the range of cutting speeds, vc = 15–40 m/min the durability of the inserts was 75% of that achieved by cubic boron nitride ones, and more than two times better than that of WC-Co cutting tools. In additional tests of machining 13CrMo4 material at an elevated cutting speed of vc = 100 m/min, binderless nWC inserts worked almost three times longer than WC-Co composites.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

scholarly journals The Role of Thin-Film Vacuum-Plasma Coatings and Their Influence on the Efficiency of Ceramic Cutting Inserts

Coatings ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 287 ◽  
Author(s):  
Marina Volosova ◽  
Sergey Grigoriev ◽  
Alexander Metel ◽  
Alexander Shein
Keyword(s):  
Bending Strength ◽  
Surface Defects ◽  
Cutting Tools ◽  
High Energy ◽  
Radius Of Curvature ◽  
Sic Ceramic ◽  
Operational Tests ◽  
Mechanical Fastening ◽  
Cutting Inserts ◽  
The Impact

The main problem with ceramics used in cutting tools is related to the unpredictable failures caused by the brittle fracturing of ceramic inserts, which is critical for the intermittent milling of cyclic loading. A 125-mm-diameter eight-toothed end mill, with a mechanical fastening of ceramic inserts, was used as a cutting tool for milling hardened steel (102Cr6). For the experiments, square inserts of the Al2O3 + SiC ceramic were used and compared with the samples made of Al2O3 + TiC to confirm the obtained results. The samples were coated with diamond-like coating (DLC), TiZrN, and TiCrAlN coatings, and their bending strength and adhesion were investigated. Investigations into the friction coefficient of the samples and operational tests were also carried out. The effect of smoothing the microroughness and surface defects in comparison with uncoated inserts, which are characteristic of the abrasive processing of ceramics, was investigated and analyzed. The process developed by the authors of the coating process allows for the cleaning and activation of the surface of ceramic inserts using high-energy gas atoms. The impact of these particles on the cutting edge of the insert ensures its sharpening and reduces the radius of curvature of its cutting edges.

Forecasting Performance of Ceramic Cutting Tool

2017 ◽  
Vol 736 ◽  
pp. 86-90 ◽  
Author(s):  
Vyacheslav Maksarov ◽  
A. Khalimonenko
Keyword(s):  
Electrical Resistance ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
Ceramic Materials ◽  
Specific Electrical Resistance ◽  
Testing Methods ◽  
Microstructural Parameters ◽  
Forecasting Performance ◽  
Nondestructive Testing Methods

The article considers the problems of forecasting the performance of cutting tools equipped with replaceable ceramic cutting bits. It is proposed to forecast the operability of ceramic tools on the ground of dependence between its performance characteristics and the microstructural parameters of the tool material. It is proposed to determine the parameters of ceramic bits microstructure by a nondestructive testing methods based on measuring the specific electrical resistance of ceramic materials. As a result of the study we have undertaken, a relationship was detected between the performance and specific electrical resistance of ceramic cutting tools.

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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