scholarly journals Method for an Effective Selection of Tools and Cutting Conditions during Precise Turning of Non-Alloy Quality Steel C45

Materials ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 505
Author(s):  
Oleksandr Ivchenko ◽  
Vitalii Ivanov ◽  
Justyna Trojanowska ◽  
Dmytro Zhyhylii ◽  
Olaf Ciszak ◽  
...  
Keyword(s):  
Extreme Values ◽  
Mathematical Formulation ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Optimality Criteria ◽  
Modern Approach ◽  
Tool Coating ◽  
Effective Selection ◽  
Specific Pair ◽  
Optimal Cutting Parameters

The paper presents a constructing methodology for a modern approach to tools selection and solving the problem of assigning optimal cutting parameters for specific production conditions. The mathematical formulation determining the extreme values of the technological process optimality criteria is obtained. A system of technical and economic quality indicators for cutting tools is proposed. This system allows principles’ implementation of decentralization and interoperability “Industry 4.0” via finite element modeling of the cutting process based on solving the problem of orthogonal free cutting modeling. The proposed methodology further usage is possible by creating a standardized database on the parameters of the tool: the adhesive component of the friction cutting coefficient for processing of a specific pair of cutting and tool materials (or tool coating material) and the impacts of the cutting-edge radius on cutting efficiency of a particular material.

scholarly journals Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1783
Author(s):  
Hamza A. Al-Tameemi ◽  
Thamir Al-Dulaimi ◽  
Michael Oluwatobiloba Awe ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Good Practice ◽  
Cutting Tools ◽  
Statistical Design ◽  
Cutting Parameters ◽  
Statistical Design Of Experiments ◽  
Hole Quality ◽  
Coated Tools ◽  
Tool Coating

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

Cloud-Based Platform for Optimal Machining Parameter Selection Based on Function Blocks and Real-Time Monitoring

2015 ◽  
Vol 137 (4) ◽  
Author(s):  
Nikolaos Tapoglou ◽  
Jörn Mehnen ◽  
Aikaterini Vlachou ◽  
Michael Doukas ◽  
Nikolaos Milas ◽  
...  
Keyword(s):  
Small And Medium Enterprises ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Numerical Control ◽  
Shop Floor ◽  
Manufacturing Equipment ◽  
Function Blocks ◽  
Information Fusion Technique ◽  
Optimal Cutting Parameters ◽  
Machining Parameter

The way machining operations have been running has changed over the years. Nowadays, machine utilization and availability monitoring are becoming increasingly important for the smooth operation of modern workshops. Moreover, the nature of jobs undertaken by manufacturing small and medium enterprises (SMEs) has shifted from a mass production to small batch. To address the challenges caused by modern fast changing environments, a new cloud-based approach for monitoring the use of manufacturing equipment, dispatching jobs to the selected computer numerical control (CNC) machines, and creating the optimum machining code is presented. In this approach the manufacturing equipment is monitored using a sensor network and though an information fusion technique it derives and broadcasts the data of available tools and machines through the internet to a cloud-based platform. On the manufacturing equipment event driven function blocks with embedded optimization algorithms are responsible for selecting the optimal cutting parameters and generating the moves required for machining the parts while considering the latest information regarding the available machines and cutting tools. A case study based on scenario from a shop floor that undertakes machining jobs is used to demonstrate the developed methods and tools.

Comparative study of tool wear in milling titanium alloy (Ti-6Al-4V) using PVD and CVD coated cutting tool

2017 ◽  
Vol 69 (3) ◽  
pp. 363-370 ◽  
Author(s):  
Raja Izamshah Raja Abdullah ◽  
Bahrin Ikram Redzuwan ◽  
Mohd Sanusi Abdul Aziz ◽  
Mohd Shahir Kasim
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Vapor Deposition ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Machining Performance ◽  
Content Type ◽  
Different Types ◽  
Optimal Cutting Parameters

Purpose The purpose of this study was to compare machining performance between chemical vapor deposition (CVD)- and physical vapor deposition (PVD)-coated cutting tools to obtain the optimal cutting parameters based on different types of tools for machining titanium alloy (Ti-6Al-4V). Design/methodology/approach The design of the experiment was constructed using the response surface methodology (RSM) with the Box–Behnken method. Two types of round-shaped tungsten carbide inserts were used in this experiment, namely, PVD TiAlN/AlCrN insert tool and CVD TiCN/Al2O3 insert tool. The titanium alloy (Ti-6Al-4V) material was used throughout this experiment. The tool wear and microstructure analysis were measured using a tool maker microscope, an optical microscope and a scanning electron machine. Findings The PVD TiAlN/AlCrN insert tool produces the lowest tool wear that significantly prolongs the cutting tool life compared to the CVD TiCN/Al2O3 insert tool. In addition, depth of cut was the main factor affecting the tool life, followed by cutting speed and feed rate. Originality/value This study was conducted to compare machining performance between CVD- and PVD-coated cutting tools to obtain the optimal cutting parameters based on different types of tools for machining titanium alloy (Ti-6Al-4V). In addition, the information presented in this paper helps reduce the manufacturing cost and setup time for machining titanium alloy. Finally, tool wear comparison between PVD- and CVD-coated titanium alloys was also presented for future improvement for tool manufacturing application.

Towards the Development of a Methodology for the Optimization of the Metal Cutting Process in Multiedge Tools From Data Collected With Single Edge Tools

2005 ◽  
Author(s):  
V. A. Acosta ◽  
J. C. Miranda
Keyword(s):  
Metal Cutting ◽  
Cutting Parameters ◽  
Single Edge ◽  
Dimensional Precision ◽  
Relevant Variables ◽  
Specific Pair ◽  
Using Data ◽  
Similar Pair ◽  
Cutting Processes ◽  
Optimal Cutting Parameters

Metal cutting processes constitute one of the more common processes in manufacturing. This is due to its versatility in obtaining different geometries and for the dimensional precision obtained in comparison with other processes. In order to optimize these processes it is necessary to understand the behavior of all involved variables which usually require running a large number of experiments for any specific pair of tool-workpiece that is evaluated. Even when several studies are available to optimize metal cutting processes, many of them are restricted to single edge tooling processes since proper experimentation in processes like milling which involve multi-edge tooling is difficult to carry out. In this sense, it becomes convenient to develop strategies that allow an engineer to optimize milling processes for a specific pair of tool-workpiece using data obtained from turning using a similar pair. In this work, the first steps followed in the development of a methodology capable of establishing optimal cutting parameters for milling from data obtained from turning is presented were relevant variables and relations between both processes are identified and evaluated.

Machinability Study on SiC Particle Reinforced Aluminum Alloy Composite (SiCp/Al) Material With CVD Diamond Coated End Mills

2017 ◽  
Author(s):  
Alexandro Vargas ◽  
Tony Nguyen ◽  
Jiancheng Liu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Silicon Carbide Particle ◽  
End Mills ◽  
Optimal Cutting Parameters ◽  
Tool Rotation

Particle-reinforced metal matrix composites (pMMC) such as silicon carbide particle reinforced aluminum alloys (SiCp/Al) require special cutting tools due to the high hardness and abrasive properties of the ceramic particles. Diamond coated cutting tools are ideal for machining this type of pMMC. Previous research studies focus on the machinability of pMMCs with low ceramic content. The aim of this research is to determine the optimal cutting parameters for machining SiCp/Al material containing high silicon carbide particle reinforcement (>25%). Material removal rate (MRR) was used to determine the optimal cutting parameters with the tool wear and surface roughness as constraints. Cutting speed, feed rate, and depth of cut were used as design parameters for the design of experiment. High burr formation and cutting forces were observed during the experiments. Experimental milling tests are conducted using CVD diamond coated end mills and non-diamond tungsten carbide end mills. It was found that low tool rotation speeds, feed rates and depths of cut are necessary to achieve smoother surface finishes of Ra < 1 μm. A high MRR to low tool wear and surface roughness ratio was obtainable at a tool rotation speed of 6500 r/min, feed rate of 762 mm/min, and depth of cut of 3 mm. Results showed that a smooth surface roughness of the workpiece material was achieved with non-diamond tungsten carbide end mills, however, this was at the expense of extreme tool wear and high burr formation. An endurance test was run to test for complete tool failure.

Rapid Parameter Optimization of High Speed Milling Aluminum Alloy Thin-Walled Workpiece

2010 ◽  
Vol 431-432 ◽  
pp. 41-44
Author(s):  
Feng Xu ◽  
Jian Jun Zhu ◽  
Xiao Jun Zang ◽  
Xin Wu
Keyword(s):  
Parameter Optimization ◽  
High Speed ◽  
Removal Rate ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Optimal Parameters ◽  
High Speed Milling ◽  
Thin Walled ◽  
Optimal Cutting Parameters

At present, the lack of the optimal cutting parameters of high speed milling is the obstacle to its widely application. In this paper, the simplified and rapid optimization method is proposed on high speed milling alloy thin-walled workpiece. The normal selection method of cutting tools and cutting conditions is put forward as the precondition of parameter optimization. The acquirement method of optimal parameters is presented. The maximal critical axial depths of cut at the different cutting conditions are achieved according to chatter stability theory. The materials removal rate is selected as the optimal objective. The optimal parameters are filtrated up and validated according to the constraint conditions including machining tool, cutting tools, surface quality and precision of the parts.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

scholarly journals A surrogate-assisted optimization approach for multi-response end milling of aluminum alloy AA3105

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2419-2439
Author(s):  
Tamal Ghosh ◽  
Yi Wang ◽  
Kristian Martinsen ◽  
Kesheng Wang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Data Driven ◽  
Optimal Cutting Parameters

Abstract Optimization of the end milling process is a combinatorial task due to the involvement of a large number of process variables and performance characteristics. Process-specific numerical models or mathematical functions are required for the evaluation of parametric combinations in order to improve the quality of the machined parts and machining time. This problem could be categorized as the offline data-driven optimization problem. For such problems, the surrogate or predictive models are useful, which could be employed to approximate the objective functions for the optimization algorithms. This paper presents a data-driven surrogate-assisted optimizer to model the end mill cutting of aluminum alloy on a desktop milling machine. To facilitate that, material removal rate (MRR), surface roughness (Ra), and cutting forces are considered as the functions of tool diameter, spindle speed, feed rate, and depth of cut. The principal methodology is developed using a Bayesian regularized neural network (surrogate) and a beetle antennae search algorithm (optimizer) to perform the process optimization. The relationships among the process responses are studied using Kohonen’s self-organizing map. The proposed methodology is successfully compared with three different optimization techniques and shown to outperform them with improvements of 40.98% for MRR and 10.56% for Ra. The proposed surrogate-assisted optimization method is prompt and efficient in handling the offline machining data. Finally, the validation has been done using the experimental end milling cutting carried out on aluminum alloy to measure the surface roughness, material removal rate, and cutting forces using dynamometer for the optimal cutting parameters on desktop milling center. From the estimated surface roughness value of 0.4651 μm, the optimal cutting parameters have given a maximum material removal rate of 44.027 mm3/s with less amplitude of cutting force on the workpiece. The obtained test results show that more optimal surface quality and material removal can be achieved with the optimal set of parameters.

Apply Image Registration to the Wear Measurement and Analysis of Different PVD-Coating Drills

2007 ◽  
Vol 359-360 ◽  
pp. 489-493
Author(s):  
Yih Chih Chiou ◽  
Yu Teng Liang
Keyword(s):  
Image Registration ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Control Factor ◽  
Drilling Force ◽  
Dry Cutting ◽  
Wear And Corrosion ◽  
Measurement And Analysis ◽  
Wear And Corrosion Resistance ◽  
Hot Hardness

PVD (Physical Vapour Deposition) multilayer coatings were extensively used in cutting tools because of their relatively high wear and corrosion resistance, adhesion strength, hot hardness, and low coefficient of friction. The object of this study is to measure flank wear of dry cutting drills of different PVD coatings, including TiN, TiCN, and TiAlN by using drilling force experiments and machine vision technique incorporated with image registration technique. To obtain an optimal combination of cutting parameters quickly, we applied Taguchi method to plan the drilling experiment. The experimental results show that coating layer is the most important control factor for cutting and the TiAlN-coating drills generate least wear and thus has the longest tool life.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

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