scholarly journals 3D Hybrid Numerical Model of Residual Stresses: Numerical—Sensitivity to Cutting Parameters When Turning 15-5PH Stainless Steel

2021 ◽  
Vol 5 (3) ◽  
pp. 70
Author(s):  
Alexandre Mondelin ◽  
Frédéric Valiorgue ◽  
Joël Rech ◽  
Michel Coret
Keyword(s):  
Stainless Steel ◽  
Residual Stresses ◽  
Hybrid Model ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Residual Stress State

This paper investigates the residual stresses induced by a longitudinal turning operation in 15-5PH martensitic stainless steel. An experimental investigation has quantified the sensitivity of residual stresses to cutting speed, feed, tool geometry and tool flank wear. In parallel, a 3D hybrid model, previously developed, has been applied to each case study. This modelling approach consists of replacing tooling and chipping by equivalent thermal and mechanical loadings. These equivalent loadings are moved onto the machined surface to compute the final residual stress state. It has shown that tool geometry and tool flank wear have a dominant effect on residual stresses compared to cutting speed and feed rate. However, cutting speed influences the intensity of the compressive peak, to some extent, whereas feed influences the affected depth. This work has also shown that the 3D hybrid model is able to predict residual stresses, as well as the sensitivity to cutting parameters, with reasonable agreement.

Role of Tool Flank Wear and Machining Speed in Developing of Residual Stress in Machined Surface During High Speed Machining of Titanium Alloys

2015 ◽  
Author(s):  
Xueping Zhang ◽  
Rajiv Shivpuri ◽  
Anil K. Srivastava
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
High Speed ◽  
Flank Wear ◽  
Tool Geometry ◽  
High Speed Machining ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machining Speed

Residual stresses generated from finish machining have a significant impact on the fatigue life of mechanical components by controlling crack initiation and propagation processes in their near subsurface. As governing variables, tool geometry, tool wear, machining parameter, work material property, and lubrication conditions have been widely studied to determine their effects on residual stress pattern in machined surface and subsurface. Among those parameters, tool flank wear was seldom fully investigated although tool flank wear, as well as machining speed, has been identified as the most important contributor to residual stress. Especially, tool flank wear becomes more significant due to the poor work thermal property during the high speed machining of titanium Ti-6Al-4V alloy. This study aims to investigate the combined role of tool flank wear and machining speed in developing residual stress in the machining of titanium alloy using finite element method. A microstructure sensitive material model based on Self Consistent Method (SCM) is adopted to incorporate the phase state and its transformations during machining cycle. Critical flank wear land and corresponding machining speeds are identified, beyond which compressive residual stresses are transferred into tensile residual stresses. High machining speeds demonstrate a distinct influence on residual stresses by means of promoting tool flank wear rate. The numerical simulation results are validated by empirical data provided in previous research.

Experimental Study on Nano-TiAlN Coated Carbide Tools in Turning Austenitic Stainless Steel

2012 ◽  
Vol 723 ◽  
pp. 247-251
Author(s):  
Hai Dong Yang ◽  
Zhi Ding
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Dry Cutting ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Austenitic stainless steel has poor cutting performance, especially when the inappropriate choice of tool materials and cutting parameters, cutting tool life will be shortened and the quality of machined surface is poor. In this paper, 0Cr18Ni9 stainless steel dry cutting tests had been done with nano-TiAlN coated carbide blade YGB202, the relationship between tool life and cutting speed, tool wear mechanism had been analyzed. In order to improve the processing efficiency and tool life, process parameters were optimized.

Built-Up-Edge Formation in Micromilling

2015 ◽  
Author(s):  
V. Kovvuri ◽  
Z. Wang ◽  
A. Araujo ◽  
M. B. da Silva ◽  
S. Bukkapatnam ◽  
...  
Keyword(s):  
Surface Finish ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Machined Surface ◽  
Area Density ◽  
Milled Surface ◽  
Chip Load ◽  
Cutting Speeds

This paper presents experimental study on conditions for built-up-edge (BUE) formation and its effects in micromilling. Surface finish and BUE area density on a micromilled surface are used to quantify the presence of BUE. A model for surface finish is derived based on the topography of milled surface and tool geometry. Assuming no BUE formation, this empirical model shows the dependence of surface finish on chip load, tool concavity angle, and includes the effect of cutting parameters and milling modes (up-milling or down-milling). Micromilling tools of 100–400 μm diameters are used for milling stainless steel at 10–60 m/min cutting speed, 0.05–1 μm/flute chip load, in minimum quality lubrication condition (MQL). A BUE, embedded onto either a milled surface or tool cutting edge or chip, is identified by scanning electron microscopy and energy dispersive spectroscopy techniques; the severity of BUE formation is quantified as area density when observing a machined surface at high magnification with optical microscopy or interferometry. Condition for BUE formation is presented by mapping the surface finish and BUE area density against cutting speed and chip load. A microtool would fracture catastrophically at high cutting speeds and/or high chip loads due to excessive dynamic stresses on a microtool; such tool would also fail at the other extreme when low cutting speeds and chip loads promote formation and detachment of BUE on the tool surface, therefore, chipping the fragile microcutting edges of a microtool. There is an optimal zone for effective micromilling without tool failure and BUEs. The measured surface finish approaches the theoretical value when BUE is absent, i.e. micromilling in minimum quantity lubrication at cutting speed between 40–60 m/min and chip load higher than 0.15μm/tooth. The BUE area density for up-milling is lower than that for down-milling at low cutting speed; such difference gradually diminishes when selecting milling parameters in the optimal zone where BUE is practically absent.

Effects of Laser Cutting Main Parameters on Microhardness and Microstructure Changes of Stainless Steel

2013 ◽  
Vol 664 ◽  
pp. 811-816 ◽  
Author(s):  
Imed Miraoui ◽  
Mohamed Boujelbene ◽  
Emin Bayraktar
Keyword(s):  
Stainless Steel ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Speed ◽  
Experimental Tests ◽  
Cutting Parameters ◽  
Surface Microstructure ◽  
Machined Surface ◽  
Microhardness And Microstructure ◽  
Cut Surface

Laser cutting of materials is becoming the preferred method of cutting. It has many advantages over conventional machining techniques such as better quality of cuts, quick and accurate cutting. The objective of this work is to investigate the effect of the main input laser cutting parameters, laser power and cutting speed, on the microhardness of stainless steel sheets obtained by CO2 laser cutting. The experimental tests were performed at various laser powers and cutting speeds. The cut surface was studied based on microhardness depth profiles beneath the machined surface. In order to investigate the metallurgical alterations beneath the cut surface, the microstructure was observed by using scanning electron microscopy. The results show that the microhardness and the surface microstructure are affected by laser cutting. Laser cutting leads to the formation of periodic striations and cracks. Also the main parameters of cutting, laser power and cutting speed, have an effect on surface microstructure and microhardness.

The influence of turning parameters on surface integrity of nickel alloy 625

2016 ◽  
Vol 232 (10) ◽  
pp. 1837-1847 ◽  
Author(s):  
Daniel Loureiro ◽  
Anselmo E Diniz ◽  
Alexandre B Farina ◽  
Sérgio Delijaicov
Keyword(s):  
Residual Stresses ◽  
Surface Integrity ◽  
Cold Work ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Machined Surface ◽  
Alloy 625 ◽  
Industrial Sectors ◽  
Coated Carbide ◽  
Compressive Residual Stresses

Nickel-based alloys are used in industrial sectors where high mechanical strength and corrosion resistance are required at high temperatures. However, these alloys have low machinability as a consequence of inherent properties. Some of these properties such as high cold work hardening rate and low heat conductivity may cause damages to the machined surface. Among the nickel-based alloys, one that has good properties for oil exploration is alloy 625. As the components made of this alloy are frequently used in very rough environments, this study sought to evaluate the influence of tool geometry, cutting conditions (feed and cutting speed) and tool condition (fresh or worn) on the surface integrity of turned alloy 625 parts in order to discover turning practices for this alloy that result in minimal damage to the workpiece surface. A secondary aim was to evaluate how these input variables affected the life of the coated carbide tools used in the turning experiments with this alloy. The main conclusions are that (a) the surfaces produced with a fresh tool with positive geometry had compressive residual stresses, while those produced with negative tool geometry had tensile residual stresses and (b) when a worn tool was used all the surfaces produced had compressive residual stresses.

scholarly journals Cutting Force and Cutting Quality during Tapered Milling of Glass Magnesium Board

2019 ◽  
Vol 9 (12) ◽  
pp. 2533
Author(s):  
Pingxiang Cao ◽  
Zhaolong Zhu ◽  
Xiaolei Guo ◽  
Xiaodong (Alice) Wang ◽  
Chunchao Fu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Tool Geometry ◽  
Cutting Condition ◽  
Cutting Depth ◽  
Machined Surface ◽  
Taper Angle

In this paper, the effects of tool geometry and cutting parameters on cutting force and quality were investigated during the tapered milling of glass magnesium (MGO) board with diamond cutters. The results were as follows: firstly, both the cutting force and roughness of the machined surface were positively correlated with the taper angle of the cutters and the cutting depth, but negatively related to the spindle speed. Then, the cutting depth had the largest influence on the cutting force and surface roughness, followed by the taper angle and spindle speed. Thirdly, the taper angle had a significant influence on the cutting force, but not on the surface roughness. The contribution of the spindle speed to both the cutting force and the surface roughness were significant, while the cutting depth had an insignificant effect on the cutting force and the surface roughness. Finally, the optimal cutting condition for the tapered milling of glass magnesium board was found to be a taper angle of 15°, a spindle speed of 5000 rpm (cutting speed of 36.63 m/s), and a cutting depth of 0.5 mm, which are proposed for industrial production in order to achieve greater cutting quality and economic benefit.

Multi-response optimization in environment friendly turning of AISI 304 austenitic stainless steel

2019 ◽  
Vol 15 (3) ◽  
pp. 538-558 ◽  
Author(s):  
Talwinder Singh ◽  
J.S. Dureja ◽  
Manu Dogra ◽  
Manpreet S. Bhatti
Keyword(s):  
Stainless Steel ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Aisi 304 Stainless Steel ◽  
Environment Friendly ◽  
Aisi 304 ◽  
Tool Flank Wear ◽  
Content Type

Purpose The purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface quality of AISI 304 stainless steel during environment friendly turning under nanofluid minimum quantity lubrication (NMQL) conditions using PVD-coated carbide cutting inserts. Design/methodology/approach Turning experiments are conducted as per the central composite rotatable design under the response surface methodology. ANOVA and regression analysis are employed to examine significant cutting parameters and develop mathematical models for VB (tool flank wear) and Ra (surface roughness). Multi-response desirability optimization approach is used to investigate optimum turning parameters for simultaneously minimizing VB and Ra. Findings Optimal input turning parameters are observed as follows: cutting speed: 168.06 m/min., feed rate: 0.06 mm/rev. and depth of cut: 0.25 mm with predicted optimal output response factors: VB: 106.864 µm and Ra: 0.571 µm at the 0.753 desirability level. ANOVA test reveals depth of cut and cutting speed-feed rate interaction as statistically significant factors influencing tool flank wear, whereas cutting speed is a dominating factor affecting surface roughness. Confirmation tests show 5.70 and 3.71 percent error between predicted and experimental examined values of VB and Ra, respectively. Research limitations/implications AISI 304 is a highly consumed grade of stainless steel in aerospace components, chemical equipment, nuclear industry, pressure vessels, food processing equipment, paper industry, etc. However, AISI 304 stainless steel is considered as a difficult-to-cut material because of its high strength, rapid work hardening and low heat conductivity. This leads to lesser tool life and poor surface finish. Consequently, the optimization of machining parameters is necessary to minimize tool wear and surface roughness. The results obtained in this research can be used as turning database for the above-mentioned industries for attaining a better machined surface quality and tool performance under environment friendly machining conditions. Practical implications Turning of AISI 304 stainless steel under NMQL conditions results in environment friendly machining process by maintaining a dry, healthy, clean and pollution free working area. Originality/value Machining of AISI 304 stainless steel under vegetable oil-based NMQL conditions has not been investigated previously.

Effect of Cutting Parameters on Integrality of Machined Surface in Hard Cutting

2004 ◽  
Vol 471-472 ◽  
pp. 307-311 ◽  
Author(s):  
Xian Li Liu ◽  
Fu Gang Yan ◽  
Y.F. Li ◽  
Yong Jun Wang ◽  
H.M. Pen
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Texture ◽  
High Efficiency ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Optimal Cutting Parameters ◽  
Hard Cutting

There is a bright future for hard cutting technique because of good machining flexibility, high efficiency, no pollution. This paper presents effect rules of cutting parameters (cutting speed, feed, depth of cutting) on integrality of machined surface (surface roughness, surface hardness, surface hardened depth, residual stresses, surface texture) based on orthogonalization test. Optimal cutting parameters are selected according to these rules. Surface roughness (Ra) is up to 0.6µm in terms of selected optimal cutting parameters.

Superficial Residual Stresses in Face-Milling the 17-4PH Stainless Steel at Various Feed Rates

2016 ◽  
Vol 693 ◽  
pp. 922-927 ◽  
Author(s):  
Guo Liang Liu ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Jun Wang ◽  
Xiang Yu Wang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Residual Stresses ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Face Milling ◽  
Stress Tests ◽  
Machined Surface ◽  
Compressive Stresses ◽  
Coated Carbide

17-4PH stainless steel is a widely used martensitic precipitation hardening stainless steel, and it is a typical difficult-to-cut material. Residual stress is an important part of the surface integrity. In this paper, superficial residual stress tests of face-milling the 17-4PH stainless steel were carried out at 0.1~0.3 mm/tooth with TiAlN coated carbide inserts. The effects of feed rate on the superficial residual stresses at various cutting speeds were studied. It was found that the residual stresses on the machined surface were very sensitive to the feed rate. The superficial residual stresses at the directions of parallel to and normal to the feed direction both remained compressive and changed obviously in higher compressive direction along with the feed rate. The burnishing effect determined by the cutting force was found to be the primary reason of the residual compressive stresses on the machined surface. The suitable cutting parameters were recommended according to the superficial residual stresses.

scholarly journals Influence of Cutting Parameters on Chatter and Tool Wear During End Milling of Stainless Steel Conducted on VMC

1970 ◽  
Vol 3 (2) ◽  
Author(s):  
A.K.M.N. AMIN, M. IMRAN AND M. ARIF
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Wear Intensity ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Milling Operation

Stainless steels are a group of difficult to machine work materials. The difficulty in machining stainless steels is manifested in high contact length and stresses, formation of serrated chips and development of chatter resulting in high tool wear rates and poor machined surface finish. The paper focuses on the performance of TiN coated-carbide inserts in machining stainless steel specimens in end milling operation performed on vertical machining centre (VMC). The performance of the tool is evaluated from the point of view of its wear intensity, mechanism of failure and generation and effect of chatter on tool wear and vice versa. The investigations were aimed at determining the effect of cutting parameters, specifically cutting speed, feed and depth of cut, on chatter amplitude, tool wear rate, mechanism of tool wear and using these data and machined surface roughness values from previous work to come up with recommended values of cutting parameters for semi-finish and finish end milling operation of stainless steel work materials. For recording vibration signals a dual channel portable signal analyzers was used and the signals were analyzed using Pulse Multi-analyzer version 4.2 software. Tool wear was measured using an optical microscope with digital readout capabilities along 3 axes. The tool wear mechanisms were studied under a scanning electron microscope (SEM). Results of the investigation show that acceleration amplitudes generally increase with cutting speed and the magnitude of tool flank wears. It has been also found that an increase in feed and depth of cut leads to higher acceleration amplitudes. The most common wear mechanisms observed during machining of stainless steel are attrition, micro and macro chipping of the tool at lower cutting speeds, and diffusion and mechanical failures due to intensive chatter at higher speeds. It has been also established that stable cutting speeds with relatively low tool wear intensity and satisfactory machined surface finish can be achieved through proper selection of cutting parameters. A table of recommended cutting conditions has been developed for almost chatter free machining with low tool wear intensity and satisfactory surface finish. Key Words: Vertical Machining Centre, Machinability, Chatter, Cutting, Tool life.

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