scholarly journals Influence of Microgroove Structure on Cutting Performance and Chip Morphology during the Turning of Superalloy Inconel 718

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4142
Author(s):  
Zhongfei Zou ◽  
Lin He ◽  
Hongwan Jiang ◽  
Sen Yuan ◽  
Zhongwei Ren
Keyword(s):  
Comparative Analysis ◽  
Cutting Force ◽  
Tool Life ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Performance ◽  
Breaking Effect ◽  
Life Tool

This study designed a new microgroove cutting tool to machine Inconel 718 and focused on the effect of microgroove structure on the cutting performance and chip morphology during the turning. A comparative analysis of the cutting force, cutting temperature, tool life, tool wear, and chip morphology of the microgroove cutting tool and the original cutting tool was conducted. The main cutting force and temperature of the microgroove cutting tool were reduced by 12% and 12.17%, respectively, compared with the original cutting tool. The microgroove cutting tool exhibited a significant improvement compared with the original cutting tool, which extended the tool life by up to 23.08%. Further, the microgroove cutting tool distorted the curl radius of the chips extensively. The experimental results showed that the microgroove structure can not only improve the tool life, but also improve the chip breaking effect.

Performance evaluation of a tungsten carbide–based self-lubricant cutting tool

2016 ◽  
Vol 232 (10) ◽  
pp. 1825-1836 ◽  
Author(s):  
Ayyankalai Muthuraja ◽  
Selvaraj Senthilvelan
Keyword(s):  
Tungsten Carbide ◽  
Cutting Force ◽  
Tool Life ◽  
Solid Lubricant ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Machined Surface ◽  
Flank Surface

Tungsten carbide cutting tools with and without solid lubricant (WC-10Co-5CaF2 and WC-10Co) were developed in-house via powder metallurgy. The developed cutting tools and a commercial WC-10Co cutting tool were used to machine cylindrical AISI 1020 steel material under dry conditions. The cutting force and average cutting tool temperature were continuously measured. The cutting tool flank surface and chip morphology after specific tool life (5 min of cutting) were examined to understand tool wear. The flank wear of the considered cutting tools was also measured to quantify the cutting tool life. The surface roughness of the workpiece was measured to determine the machining quality. The developed cutting tool with solid lubricant (WC-10Co-5CaF2) generated 20%–40% less cutting force compared to that of the developed cutting tool without solid lubricant (WC-10Co). In addition, the finish of the workpiece surface improved by 16%–20% when it was machined by the solid lubricant cutting tool. The cutting tool with solid lubricant (WC-10Co-5CaF2) exhibited a 15%–18% reduction in flank wear. Curlier and smaller saw tooth chips were generated from the WC-10Co-5CaF2 cutting tool, confirming that less heat was generated during the cutting process, and the finish of the machined surface was also improved.

Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface

2017 ◽  
Vol 233 (1) ◽  
pp. 18-30 ◽  
Author(s):  
Jian-wei Ma ◽  
Zhen-yuan Jia ◽  
Guang-zhi He ◽  
Zhen Liu ◽  
Xiao-xuan Zhao ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Tool ◽  
Helix Angle ◽  
Curved Surface ◽  
Geometrical Parameters ◽  
High Speed Milling

High-speed machining provides an efficient approach for machining Inconel 718 with high quality and high efficiency. For high-speed milling of Inconel 718 curved surface, the geometrical characteristics are changing continuously leading to a sharp fluctuation of cutting force, which will aggravate the tool wear. As the wear mechanism of coated cutting tool is seriously affected by the cutting tool geometrical parameters, suitable geometrical parameters of cutting tool should be selected to avoid the cutting tool from being worn out very quickly. In this study, the influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface is investigated with coated cutting tool, and the cutting force in milling process is also analyzed. The results show that the cutting force variation can manifest the tool wear degree, and the failure type of coated cutting tool in plane milling and curved surface milling after the same cutting length is different. Furthermore, the cutting tool geometrical parameters seriously affect the tool wear and the tool life in high-speed milling of Inconel 718 curved surface. Concretely, the small rake angle has greater strength and has superiority, the relief angle increasing can enhance the tool life, and the tool life is decreased with the increasing of helix angle for the cutting tool, whose helix angle is larger than 30°. This study provides a theoretical basis for cutting tool wear mechanism and cutting tool geometrical parameter selection in high-speed milling of Inconel 718 curved surface, so as to guarantee the machining efficiency in high-speed milling of Inconel 718 curved surface.

Finite Element Investigation of Cutting Performance of Cr/W-DLC/DLC Composite Coated Cutting Tool

2021 ◽  
Author(s):  
Tianmei Hao ◽  
Jin Du ◽  
Xue Zhang ◽  
Guosheng Su ◽  
Peirong Zhang ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Cutting Force ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Interface Temperature ◽  
Machined Surface ◽  
Heat Partition ◽  
Coated Tools ◽  
Cutting Deformation

Abstract Coupled with a thermo-mechanical metal cutting process, rapid tool wear, higher surface roughness and mass heat are caused by the rapid plastic deformation of the workpiece and by the friction along the tool-chip interface. This phenomenon is more predominant in the machining of difficult-to-cut materials. DLC film has been applied as coating material in the machining of difficult-to-cut materials, and shows a good cutting performance. In this study, Cr/W-DLC/DLC coated tools were compared with other three coated tools (i.e., TiC-, TiAlN-, Al 2 O 3 -) to investigate the cutting performance in the machining of Al-Si alloy (AC9B). In addition, the influence of Cr/W-DLC/DLC coated tools on the cutting performance under different cutting speeds was studied. Cutting force, cutting temperature, heat transfer coefficient of the rake face of the tool, cutting deformation rate, plastic deformation of machined surface, the interface temperature and stress were investigated numerically based on Finite Element Method (FEM). Actual cutting experiments were carried out to the verification of the FEM models by means of the cutting force and cutting temperature measurement. The investigation results showed that Cr/W-DLC/DLC coated tools has the lowest cutting force and cutting temperature, good cutting deformation characteristics and lower coating-substrate interface temperature and stress, however appears the maximum value of heat partition coefficient into the cutting tool. With the increasing of cutting speeds, cutting force and cutting temperature showed an increase trend, while the plastic deformation depth of machined surface and heat partition into cutting tool all showed a decrease trend. This investigation can provide the theory basis or technical guidance for the cutting practice of Cr/W-DLC/DLC coated tools.

Study on the Machinability of Free-Cutting Steels 1214 and 12L15 with Coated Tool

2012 ◽  
Vol 426 ◽  
pp. 151-154 ◽  
Author(s):  
Ying Ying Wei ◽  
Zhi Qiang Liu ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Environmental Friendly ◽  
Coated Tool ◽  
Orthogonal Tests

Research has been done on machinability of two different kinds of free-cutting steels by using coated cutting tool at the condition of different cutting parameters. Orthogonal tests are adopted in order to compare the cutting performance of the two materials. The cutting force, surface roughness, chip morphology and tool wear are investigated, which reveal the influence of Pb and other composition on machinability. The experiment shows that 1215 has more or less better performance than 12L14. It is of great significance for the development of environmental friendly products.

Experimental Study of Cutting Performance for Inconel 718 Milling by Various Assisted Machining Techniques

2019 ◽  
Vol 294 ◽  
pp. 129-134
Author(s):  
Shen Yung Lin ◽  
Bing Hsueh Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Process Parameter ◽  
Spindle Speed ◽  
Cutting Performance ◽  
Subsequent Stage ◽  
Cutting Depth ◽  
Tool Service Life

The five stage experiments including without assistance, single and hybrid assisted machining systems on Inconel 718 milling were conducted in this study. First of all, the milling experiment without assistance was performed to investigate the variations of cutting performance and the results were used for a suitable process parameter planning in the subsequent stage experiments. Next, a laser assisted system was introduced in the second stage where the spacing distance between the laser spot and cutting-tool along the cutting direction was modified to test whether laser preheating may effectively reduce the cutting force. A biaxial ultrasonically assisted system with only one-axis oscillation (x or y direction) and with two-axis simultaneous oscillations (x and y directions) were subsequently introduced at the third to fourth stage experiments, respectively. While a biaxial ultrasonically and the laser assisted systems were integrated together to construct a hybrid assisted cutting system at the last stage experiment. Under these assistances, milling experiments of Inconel 718 by cutting-tool of tungsten carbide with nanoSi® coating were conducted. And the full-factorial experiments of process parameter combinations such as spindle speed, radial cutting depth and feed rate were planned. The results indicated that the laser-preheating assisted system could effectively reduce the cutting force as well as enhance the cutting performance. The effect of the biaxial ultrasonic oscillation on tool service life could greatly be promoted. Furthermore, the cutting performance exhibited in the integrated hybrid assisted milling prevails over that in milling without assistance as well as with each single assisted system. Under this hybrid assisted milling, the better surface roughness of 0.216μm was obtained under a combination of spindle speed of 6000 rpm, radial cutting depth of 0.01 mm, and feed rate of 300mm/min, accompanied by a maximum cutting-tool wear of 13.849μm.

Performance Evaluation of Cryogenic Treated and Untreated Carbide Inserts during Machining of AISI 304 Steel

2020 ◽  
Vol 17 (1) ◽  
pp. 7709-7718
Author(s):  
Nagraj Patil ◽  
K. Gopalakrishna ◽  
B. Sangmesh
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cutting Tool ◽  
Cryogenic Treatment ◽  
Multilayer Coating ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Aisi 304 ◽  
Aisi 304 Steel

The cutting tool in the machining process plays an important role as it acts on the working material. There are a few methodologies have been persued to improve tool life, for example traditional cooling, single layer coating, multilayer coating, heat treatment process, nitrogen cooling and latest being the cryogenic treatment which reported a significant improvement in cutting tool life, chip morphology, reduction in heat generation. Hence, the cryogenic treatment is emerged as the sustainable machining process.  This paper presents machining of AISI 304 steel using both cryogenic treated (CT) and untreated (UT) cutting tool insert. The commercially available uncoated carbide insert has been cryogenically treated at -196°C for 24 hours soaking period. The machining test has been  conducted under four different cutting speeds. The material characterization of cutting insert is studied by using scanning electron microscopy (SEM), hardness test, and microscopic image analysis has been carried out before and after cryogenic treatment. The cutting tool performance is assessed in terms of of wear, cutting temperature, chip morphology, surface roughness under the influence of cryogenic machining and the results are contrast with UT one. The exploratory findings reveals that the deep cryogenic treatment (DCT) with 24 hours soaking period, performed better wear resistance and improved surface roughness of the cutting tool. Also considerable reduction in the flank wear, crater wear, cutting temperature is obtained and found improved chip morphology.

Cutting Performance of Cemented Carbide Tool in High-Efficiency Turning Ti6Al4V

2012 ◽  
Vol 522 ◽  
pp. 231-235 ◽  
Author(s):  
Yi Hang Fan ◽  
Min Li Zheng ◽  
Zhe Li ◽  
Song Tao Wang ◽  
Ying Bin Li
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Carbide Tool ◽  
Cemented Carbide Tool ◽  
Coated Carbide

The machining efficiency of titanium alloy Ti6Al4V is low and the tool wear is serious. In this paper, uncoated carbide tool and two kinds of coated cemented carbide tool were used for dry turning titanium alloy. The experiments used CCD Observing System and the EDAX analysis of SEM to study tool wear mechanism and analyze the cutting performance through tool life, cutting force and cutting temperature. The results show that the main wear reasons are adhesion, diffusion and oxidation wear. For coated tool, the coating peeled off first, and then tool substrate damaged. Compared with coated carbide tool, the uncoated carbide tool with fine grain has longer tool life and lower cutting force and cutting temperature. The changes of cutting force and cutting temperature with cutting speed are not obvious when using the ccomposite coating (TiAlN and AlCrN) carbide tool. The results can help to choose tool material reasonably and control tool wear.

scholarly journals Preparation and cutting performance of nano-scaled Al2O3-coated micro-textured cutting tool prepared by atomic layer deposition

2021 ◽  
Vol 40 (1) ◽  
pp. 77-86
Author(s):  
Siwen Tang ◽  
Pengfei Liu ◽  
Zhen Su ◽  
Yu Lei ◽  
Qian Liu ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Atomic Layer Deposition ◽  
Cutting Force ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Atomic Layer ◽  
Cutting Performance ◽  
Cutting Test ◽  
Layer Deposition

Abstract Al2O3 nano-scaled coating was prepared on micro-textured YT5 cemented carbide cutting tools by atomic layer deposition ALD. The effect of Al2O3 nano-scaled coating, with and without combined action of texture, on the cutting performance was studied by orthogonal cutting test. The results were compared with micro-textured cutting tool and YT5 cutting tool. They show that the micro-texture and nano-scaled Al2O3 coated on the micro-texture both can reduce the cutting force and friction coefficient of the tool, and the tools with nano-scaled Al2O3 coated on the micro-texture are more efficient. Furthermore, the friction coefficient of the 100 nm Al2O3-coated micro-texture tool is relatively low. When the distance of the micro-pits is 0.15 mm, the friction coefficient is lowest among the four kinds of pit textured nanometer coating tools. The friction coefficient is the lowest when the direction of the groove in strip textured nanometer coating tool is perpendicular to the main cutting edge. The main mechanism of the nanometer Al2O3 on the micro-textured tool to reduction in cutting force and the friction coefficient is discussed. These results show that the developed tools effectively decrease the cutting force and friction coefficient of tool–chip interface.

Study of the Effect of Tool Wear on Cutting Ti6Al4V Process

2013 ◽  
Vol 690-693 ◽  
pp. 2030-2035
Author(s):  
Shu Bao Yang ◽  
Hong Chao Ni ◽  
Guo Hui Zhu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Key Factors ◽  
Serrated Chip ◽  
Comprehensive Properties ◽  
Commercial Applications ◽  
On Chip ◽  
Rapid Tool

Ti6Al4V alloy is widely used in the aircraft industry, marine and the commercial applications due to its excellent comprehensive properties. However, its poor machinability prevents it from application widely, and the rapid tool wear is one of the key factors. The FEM models of cutting titanium alloy are established. The effect of tool wear on chip morphology, cutting temperature and cutting force are studied. The simulation results show that: the cutting force and cutting temperature will rise with the increase of tool wear. Furthermore, the degree of chip deformation will improve, but the frequency of serrated chip tooth occurred will decrease.

Current Progresses of Laser Assisted Machining of Aerospace Materials for Enhancing Tool Life

2013 ◽  
Vol 690-693 ◽  
pp. 3359-3364
Author(s):  
Shou Jin Sun ◽  
Milan Brandt ◽  
John P.T. Mo
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
State Of The Art ◽  
Aerospace Industry ◽  
Cutting Temperature ◽  
Machining Process ◽  
Metallic Materials ◽  
Aerospace Materials ◽  
Beam Position ◽  
Laser Assisted Machining

A higher strength and heat resistance are increasingly demanded from the advanced engineering materials with high temperature applications in the aerospace industry. These properties make machining these materials very difficult because of the high cutting forces, cutting temperature and short tool life present. Laser assisted machining uses a laser beam to heat and soften the workpiece locally in front of the cutting tool. The temperature rise at the shear zone reduces the yield strength and work hardening of the workpiece, which make the plastic deformation of the hard-to-machine materials easier during machining. The state-of-the-art, benefits and challenges in laser assisted machining of metallic materials are summarized in this paper, and the improvement of tool life is discussed in relation to laser power, beam position and machining process parameters.

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