scholarly journals Tool Wear Analysis during Ultrasonic Assisted Turning of Nimonic-90 under Dry and Wet Conditions

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1253
Author(s):  
Jay Airao ◽  
Chandrakant K. Nirala ◽  
Luis Noberto López de Lacalle ◽  
Navneet Khanna
Keyword(s):  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Feed Force ◽  
Ultrasonic Assisted ◽  
Dry Conditions ◽  
Dry And Wet Conditions ◽  
Processing Zone ◽  
Coated Carbide

Nickel-based superalloys are widely used in the aerospace, automotive, marine and medical sectors, owing to their high mechanical strength and corrosion resistance. However, they exhibit poor machinability due to low thermal conductivity, high shear modulus, strain hardening, etc. Various modifications have been incorporated into existing machining techniques to address these issues. One such modification is the incorporation of ultrasonic assistance to turning operations. The assisted process is popularly known as ultrasonic assisted turning (UAT), and uses ultrasonic vibration to the processing zone to cut the material. The present article investigates the effect of ultrasonic vibration on coated carbide tool wear for machining Nimonic-90 under dry and wet conditions. UAT and conventional turning (CT) were performed at constant cutting speed, feed rate and depth of cut. The results show that the main wear mechanisms were abrasion, chipping, notch wear and adhesion of the built-up edge in both processes. However, by using a coolant, the formation of the built-up edge was reduced. CT and UAT under dry conditions showed an approximate reduction of 20% in the width of flank wear compared to CT and UAT under wet conditions. UAT showed approximate reductions of 6–20% in cutting force and 13–27% in feed force compared to the CT process. The chips formed during UAT were thinner, smoother and shorter than those formed during CT.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

Comparative experimental research in turning of 304 austenitic stainless steel with and without ultrasonic vibration

2016 ◽  
Vol 231 (15) ◽  
pp. 2885-2901 ◽  
Author(s):  
Yingshuai Xu ◽  
Ping Zou ◽  
Yu He ◽  
Shuo Chen ◽  
Yingjian Tian ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Wear ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
304 Austenitic Stainless Steel ◽  
Machining System

The aim of this paper is to present an experimental investigation of the cutting forces, surface quality, tool wear and chip shape in ultrasonic vibration assisted turning (UAT) of 304 austenitic stainless steel (ASS 304) in comparison to conventional turning (CT). This study focuses on the solution of the machining difficulties of ASS 304 and high demands for the processing quality and efficiency. The machining system of UAT is schemed out to assure the desired machining effect by utilizing ultrasonic vibration method. Meanwhile, a series of systematic experiments are performed with and without ultrasonic vibration using the designed machining system of UAT with cemented carbide coated cutting tool. The results obtained from the UAT and CT experiments demonstrate that the cutting effect of UAT is much better than that of CT. Furthermore, the results of this research indicate that the ultrasonic amplitude, cutting speed, feed rate and depth of cut in UAT of ASS 304 have visible influence on the cutting forces, surface quality and tool wear. And reasonable selection of various technological variables in UAT can obtain lower cutting forces, more superior surface roughness, advantageous surface topography, slow and less tool wear, thin and smooth chips.

Magnetic Damping in Turning of Stainless Steel AISI 304 for the Reduction of Machining Vibration and Tool Wear

2015 ◽  
Vol 1115 ◽  
pp. 100-103
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Siti Aminatuzzuhriyah B. Haji Subir ◽  
Fawaz Mohsen Abdullah
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Aisi 304 ◽  
Excited Vibration ◽  
Coated Carbide

Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.

Finite Element Analysis of Ultrasonic Vibration Assisted Turning of Ferrous Metals

2013 ◽  
Vol 567 ◽  
pp. 33-38 ◽  
Author(s):  
Lai Zou ◽  
Ming Zhou
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Technological Parameters ◽  
Ferrous Metals

Ultrasonic vibration assisted turning has significant improvements in processing of intractable materials compared to conventional turning. This paper presents a theoretical investigation of tool wear in single point diamond turning of ferrous metals based on numerical simulation. Finite element modeling and simulation of ultrasonic vibration turning process were performed, aimed at optimizing a series of technological parameters in the process of machining, reducing tool wear and improving surface quality as much as possible. The results revealed that the cutting speed and depth of cut are two crucial factors for tool wear, unlike the other parameters of vibration frequency, amplitude and flank angle. Moreover, this technological measure has observably decreased the cutting force and cutting temperature, so as to obtain superior surface finish.

Tool Wear Analysis of Al 6061 Reinforced with 10 wt% Al2O3 Using High Hardened Inserts

2015 ◽  
Vol 787 ◽  
pp. 643-647
Author(s):  
M. Vignesh ◽  
K. Venkatesan ◽  
R. Ramanujam ◽  
Sundaravel Vijayan
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Stir Casting ◽  
Depth Of Cut ◽  
Machining Time ◽  
Al 6061 ◽  
Optimum Cutting ◽  
Coated Carbide

Metal matrix composites (MMC) are the combination of base metal matrix and reinforcing materials like SiC, Al2O3, etc. The present research is focused on the machinability studies of Al 6061 reinforced with 10% wtof Al2O3 particles using multi layered coated carbide inserts. Fabricated samples by stir casting route were turned by the most variable factors, cutting speed, depth of cutand by a constant feed rate of 0.206 mm/rev. Surface roughness and tool wear are considered asoutput. Experiments are conducted by varying the cutting speed while keeping feed rate and depth of cut as constant. After the optimum cutting speed was determined, the depth of cut is varied by keeping the cutting speedand feed rateas constant.Based on the optimum cutting speed (150 m/min), depth of cut (1.2 mm) and feed rate (0.206 mm/rev), a long run test was carried out to find out the tool life and surface finish. But due to the softness nature built up edge formation is obtained. At the optimal parametric combination, the built up edge obtained is less than 2 mm for a machining time of 425 s

scholarly journals Machinability Investigations on Aerospace Custom 450 Alloy Using TiAlN/TiCN, TiCN/TiAlN Coated and Uncoated Carbide Tools

2021 ◽  
Vol 54 (2) ◽  
pp. 325-334
Author(s):  
Sampath Kumar Thepperumal ◽  
Vignesh Margabandu ◽  
Ramanujam Radhakrishnan ◽  
John Rajan Amaladas ◽  
Shri Vignesh Ananthakrishnan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Optimal Level ◽  
Depth Of Cut ◽  
Electron Microscopic ◽  
Utility Concept ◽  
Coated Tool ◽  
Coated Carbide

In this present research, the machinability studies of TiAlN/TiCN, TiCN/TiAlN coated and uncoated inserts were investigated on machining custom 450 alloy. The machining input parameters such as feed rate (f), cutting speed (V) and depth of cut (d) are set using orthogonal array. The machining output parameters such as surface roughness, tool wear and cutting forces were studied for its parametric contribution and it was analyzed using Analysis of Variance (ANOVA). Further, the tool wear obtained was studied using scanning electron microscopic images and energy dispersive spectroscopy analysis was conducted to check the addition of work material elements to the coated tool surface. The results show that, the feed rate is the most contributing factor in deciding resultant forces, surface roughness and tool wear respectively. TiAlN/TiCN coated carbide tool has obtained improved machinability, when compared to TiCN/TiAlN coated carbide and uncoated carbide inserts. To obtain one optimal level for all three responses of three types of tools, multi criteria decision making approach, named utility concept approach is selected. Based on the MCDM analysis, it is found that trial number 4 gives better experimental output of improved surface integrity, lower resultant force and less tool wear for all types of tools.

Tool Wear Behavior in μ-turning of Nimonic 90 Under Vegetable Oil-Based Cutting Fluid

2021 ◽  
Author(s):  
Jay Airao ◽  
Hreetabh Kishore ◽  
Chandrakant Kumar Nirala
Keyword(s):  
Tool Wear ◽  
Vegetable Oil ◽  
Wear Behavior ◽  
Cutting Speed ◽  
High Hardness ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Tool Wear Mechanism ◽  
Dry Conditions

Abstract The characteristics such as high hardness and shear modulus, low thermal conductivity, strain hardening of Nickel-based superalloys lead to high machining forces and temperature, poor surface quality and integrity, rapid tool wear, etc. The present article investigates the tool wear mechanism of the tungsten carbide (WC) tool in µ-turning of Nimonic 90 under dry, wet, and vegetable oil-based cutting fluid (VCF). Canola oil is used as vegetable oil. Three different combinations of cutting speed, feed rate, and depth of cut are considered for analysis. The tool wear is characterized using optical and scanning electron microscopy. Machining with VCF shows an approximate reduction of flank wear width in the range of 12%-52% compared to dry and wet conditions. The main wear mechanisms observed on the tool flank and rake face are abrasion, built-up edge adhesion, and edge chipping. The VCF considerably reduces the adhesion and abrasion and, hence, increases tool life. The chips produced in dry conditions are found fractured and uneven, whereas, it had an uneven lamella structure in wet conditions. The VCF found reducing the plastic deformation in each cutting condition, as a result, producing fine lamella structured chips.

Preheating in End Milling of AISI D2 Hardened Steel with Coated Carbide Inserts

2009 ◽  
Vol 83-86 ◽  
pp. 56-66 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
A.M.K. Hafiz
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Inductive Heating ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Coated Carbide

This study was conducted to investigate the effect of preheating through inductive heating mechanism in end milling of AISI D2 hardened steel (60-62 HRC) by using coated carbide tool inserts. Apart from preheating, two other machining parameters such as cutting speed and feed were varied while the depth of cut constant was kept constant. Tool wear phenomenon and machined surface finish were found to be significantly affected by preheating temperature and other two variables. End milling operation was performed on a Vertical Machining Centre (VMC). Preheating of the work material to a higher temperature range resulted in a noticeable reduction in tool wear rate leading to a longer tool life. In addition, improved surface finish was obtained with surface roughness values lower than 0.4 μm, leaving a possibility of skipping the grinding and polishing operations for certain applications.

The Use of TiAlN Coated Carbide Tool when Finish Machining Stainless Steel

2012 ◽  
Vol 224 ◽  
pp. 204-207
Author(s):  
Jozef Jurko ◽  
Anton Panda ◽  
Marcel Behún
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Stainless Steels ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Austenitic Stainless Steels ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Cutting Zone ◽  
Coated Carbide

This article presents conclusions of use TiAlN at drilling of a new austenitic stainless steels. This article presents the results of experiments that concerned the verification of the cutting tool wear. The results of cutting zone evaluation under cutting conditions (cutting speed vc=60 m/min, depth of cut ap= 3.0 mm and feed f= 0.04 mm per rev.) .

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