scholarly journals Effects of Trace Elements on the Microstructural and Machinability Characteristics of Al–Si–Cu–Mg Castings

Materials ◽  
2022 ◽  
Vol 15 (1) ◽  
pp. 377
Author(s):  
Yasser Zedan ◽  
Agnes M. Samuel ◽  
Herbert W. Doty ◽  
Victor Songmene ◽  
Fawzy H. Samuel
Keyword(s):  
Electron Microscopy ◽  
Trace Elements ◽  
Tool Wear ◽  
Tool Life ◽  
Cutting Forces ◽  
Test Results ◽  
Optical And Electron Microscopy ◽  
Life Tool ◽  
Chip Shape ◽  
Heat Treated

This study was undertaken to emphasize the influence of Sn and Bi addition on the machinability of Sr-modified, grain-refined, and heat-treated Al–Si B319 and 396 alloys. Drilling and tapping tests were conducted to examine the cutting forces, tool life, tool wear, built-up edge evolution, and chip shape. Microstructures were examined using optical and electron microscopy. Drilling test results show that the B319.2 alloy with 0.15%Sn yields the longest drill life, i.e., twice that of the B319.2 alloy containing 0.5%Bi, and one-and-a-half times that of the B319.2 alloy containing 0.15%Sn + 0.5%Bi. The presence of 0.5%Bi in the B319.2 alloy causes a deterioration of drill life (cf., 1101 holes with 2100 holes drilled in the B319.2 alloy containing 0.15%Sn). The α-Fe phase in the 396 alloy produces the highest number of holes drilled compared with alloys containing sludge or β-Fe. The presence of sludge decreases the drill life by 50%. Built-up edge (BUE) measurements and optical photographs show little change in the BUE width for different numbers of holes except for the B319.2 alloy containing 0.5%Bi, which shows a slightly lower width (0.166 mm) compared with that containing 0.15% Sn (0.184 mm) or 0.15%Sn + 0.5%Bi (0.170 mm).

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

Improvement of Tool Life of a Commercial Drill Bits by Cryogenic Treatment While Machining Widmanstatten Ti-6Al-4V.

2021 ◽  
Author(s):  
Abdullah Sert ◽  
Fatih Hayati ÇAKIR
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cryogenic Treatment ◽  
Cutting Tools ◽  
Drill Bit ◽  
Deep Cryogenic Treatment ◽  
Drill Bits ◽  
Stereo Microscope

Abstract In this study, the performance of Ø 8 mm WC-Co (10%) drill bits with a TiAlN coating was tested for machining of Ti6Al4V alloy with a Widmanstatten structure. In order to improve the tool life, cutting tools were subjected to deep cryogenic treatment. In total, three groups of tools were prepared for this study. The first group was used for reference as the supplied state; the second group was subjected to 24 hours deep cryogenic treatment at -196 ° C, and the third group was subjected to 24 hours deep cryogenic at -196 ° C, additionally was tempered 2 hours at 200 ° C. Machining experiments were done by drilling and a set of 60 holes were drilled with each drill bit, and tool wear were observed and recorded with a stereo microscope. Additionally, Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) analyses were carried on to understand the tool wear better. The microhardness of Cryo-treated and tempered cutting tools hardness increased up to 20 Hv (about 1%), and the toughness value did not change significantly. Cutting performance was observed by measuring the cutting forces during drilling experiments. According to these results, deep cryogenic treatment on WC-Co-based inserts decreased cutting forces by approximately 7% compared to the reference drill bit, which affected the cutting tool life. The dominant wear mechanism was Built-up edge (BUE) formation, and cryo-treatment lowered the BUE amount 8% and cryo-treated and tempered drill bit 45% compared to the reference drill bit.

Rapid Selection of Milling Tools Based on the Initial Wear

2011 ◽  
Vol 188 ◽  
pp. 416-422
Author(s):  
H. Zhang ◽  
Wu Yi Chen
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Tool Life ◽  
Selection Method ◽  
Statistical Regularity ◽  
Life Tool ◽  
Milling Tool ◽  
Cutting Length ◽  
Milling Tools ◽  
Selection Of

In this paper, tool life, tool wear criteria, initial wear and cutting length at initial wear are picked out from 295 milling tool wear curves to calculate initial wear rate K0, final wear rate K1 and the ratio K between the two. By statistic analysis of K0, K1 and K, a statistical regularity between K0 and K1 is found, which indicates that the faster the initial wear, the shorter the tool life would be. Based on the statistical regularity, a milling tool rapid selection method is proposed, and an experiment on selecting the best tools for machining TC4 is carried out to verify the method. The results show that the method can reduce the consumption of material and time significantly, which confirm the efficiency of the method.

Estimation of tool wear according to cutting forces during machining procedure

Sensor Review ◽  
2018 ◽  
Vol 38 (2) ◽  
pp. 176-180 ◽  
Author(s):  
Obrad Anicic ◽  
Srdjan Jovic ◽  
Nenad Stanojevic ◽  
Mladen Marsenic ◽  
Branko Pejovic ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Machining Parameters ◽  
Experimental Conditions ◽  
Experimental Procedure ◽  
Content Type ◽  
Chip Shape ◽  
Universal Microscope ◽  
The Given ◽  
The Relationship

Purpose The main purpose of the study was to analyze the relationship between cutting forces and tool wear during turning of steel 30CrNiMo8. Design/methodology/approach It is very important to find the optimal machining conditions to increase the tool life and to improve product quality. Width of tool wear was measured by universal microscope. Findings During experimental procedure, one chip shape was obtained for the given machining parameters. Results showed negligible tool wear for the given experimental conditions. In other words, the tool wear is negligible for one chip shape. Originality/value To increase tool wear, there are different chip shapes.

scholarly journals The Effects of Cooling Applications on Tool Life, Surface Quality, Cutting Forces and Cutting Zone Temperature in Turning of Ni-Based Inconel 625

2021 ◽  
Author(s):  
Selçuk YAĞMUR
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Inconel 625 ◽  
Cutting Zone ◽  
Cutting Zone Temperature ◽  
Cooling Methods ◽  
Zone Temperature

Abstract Nickel-based super alloys are used in many fields, especially in the aviation and aerospace industries, due to their high temperature resistance. Besides these advantages, there are some machining difficulties. Some cooling methods are used to minimize the machining difficulties of these materials. For this purpose, in this study, tool life, tool wear (Vb), surface roughness (Ra), cutting forces (Fc) and cutting zone temperature (T) were investigated in turning Inconel 625 super alloys under different cooling conditions. Experiments were carried out under three different cutting conditions (Dry, minimum quantity lubrication (MQL) and Vortex cooling methods). Three feed rates (0.08, 0.1 and 0.12 mm/rev) and three cutting speeds 60, 80, 100 m/min) were used. Tool wear tests were carried out at average cutting speed and feed rate (80 m/min and 0,1 mm/rev). After the experiments, it was concluded that the cooling application affects positively in terms of tool life, cutting zone temperature and surface roughness.

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