scholarly journals Study on Performance of PVD AlTiN Coatings and AlTiN-Based Composite Coatings in Dry End Milling of Hardened Steel SKD11

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 2019
Author(s):  
Lulu Jing ◽  
Ming Chen ◽  
Qinglong An
Keyword(s):  
End Milling ◽  
Composite Coatings ◽  
Multilayer Coating ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Milling ◽  
Machined Surface ◽  
Cutting Energy

Dry milling of hardened steel is an economical and environmentally friendly machining process for manufacturing a mold and die. Advances in coating technology makes the dry milling a feasible approach instead of a traditional grinding process. However, the cutting condition is particularly severe in a dry machining process. High-performance coating is desired to meet the requirement of green and highly efficient manufacturing. This study concerned the performance of AlTiN-based coatings. The effect of Al content, and the AlTiN composite coating on the cutting performance of tools are investigated in terms of friction force at the tool–chip interface, specific cutting energy, cutting temperature on the machined surface, tool wear pattern and mechanism, and surface integrity. The results show that advanced AlTiN-based coatings reduce the force and cutting energy and protect the cutters from the high cutting temperature effectively. The main wear mechanisms of the coated tools are adhesive wear, chipping induced by fatigue fracture and abrasive wear. In general, the dry milling of hardened steel with AlTiN-based coatings gains a quite satisfactory surface quality. Furthermore, AlTiN-WC/C hard-soft multilayer coating performs well in reducing cutting force, preventing adhesion wear and isolating the cutting heat, being suitable for dry milling of hardened SKD11.

Research on High-Speed Cutting of Cr12MoV Hardened Steel - A Review

2020 ◽  
Vol 15 ◽  
Author(s):  
Fei Sun ◽  
Guohe Li ◽  
Qi Zhang ◽  
Meng Liu
Keyword(s):  
High Speed ◽  
Cutting Temperature ◽  
High Hardness ◽  
High Strength ◽  
Hardened Steel ◽  
Parameters Optimization ◽  
Future Research ◽  
High Speed Machining ◽  
Machined Surface ◽  
Stamping Die

: Cr12MoV hardened steel is widely used in the manufacturing of stamping die because of its high strength, high hardness, and good wear resistance. As a kind of mainstream cutting technology, high-speed machining has been applied in the machining of Cr12MoV hardened steel. Based on the review of a large number of literature, the development of high-speed machining of Cr12MoV hardened steel was summarized, including the research status of the saw-tooth chip, cutting force, cutting temperature, tool wear, machined surface quality, and parameters optimization. The problems that exist in the current research were discussed and the directions of future research were pointed out. It can promote the development of high-speed machining of Cr12MoV hardened steel.

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

Prediction on Cutting Heat of the Simulation in NC Lathe

2012 ◽  
Vol 217-219 ◽  
pp. 1978-1982
Author(s):  
Jing Li ◽  
Yang Jiao ◽  
Zhan Li Wang ◽  
Fu Zhi Huang
Keyword(s):  
Cutting Temperature ◽  
Machining Process ◽  
Deformation Analysis ◽  
Operating Life ◽  
Machined Surface ◽  
Finite Element Software ◽  
Cutting Heat ◽  
Changing Trend ◽  
Variable Condition ◽  
Physical Phenomena

Cutting heat and cutting temperature are the most important physical phenomena in cutting machining process. Cutting temperature and its distribution affect the abrasion of cutting tool and the operating life directly. Meanwhile they can affect the machining precision and the machined surface quality. In this paper the ABAQUS finite element software is used to predict the thermal distribution and variable condition, moreover it is tested through the experiment. As is shown from the result, the changing trend of cutting temperature by the simulation is consistent with the real measured result, which has better precision and reliability and supplies the theoretical basis for the deformation analysis caused by cutting heat in the cutting machining process.

EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

2019 ◽  
Vol 234 (4) ◽  
pp. 701-709
Author(s):  
Tao Chen ◽  
Weijie Gao ◽  
Guangyue Wang ◽  
Xianli Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Two Sides

Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

Study on Cutting Temperature Modeling of Machined Workpiece in End Milling In-Situ TiB2/7050Al MMCs

2018 ◽  
Author(s):  
Yifeng Xiong ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin
Keyword(s):  
Heat Source ◽  
Metal Cutting ◽  
End Milling ◽  
Great Influence ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Temperature Model ◽  
Machined Surface ◽  
Temperature Modeling

During metal cutting, it is well known that the cutting temperature has great influence on the machined surface integrity, especially on the residual stress and machining defects. At present, a lot of analytical modeling work has been done on the cutting temperature of tool, chips and workpiece machined by the side cutting edge during end milling process. To the workpiece surface machined by the bottom cutting edge, the study of temperature modeling is rarely reported. Besides, as a new kind of particulate metal matrix composites (MMCs) with improved mechanical and physical properties, the machining study of in-situ TiB2/7050Al MMCs is not many and no analytical temperature modeling of MMCs has been published up to now. Our study aims to establish an analytical cutting temperature model of workpiece machined by the bottom cutting edge in end milling in-situ TiB2/7050Al MMCs. In this model, the moving heat source method was applied. To meet the actual cutting process, the effect of heating time was also taken into account. With validation, the temperature model shows good agreement with experimental results. It was found that the heat partition ratio conducted from the shear plane heat source to the workpiece increased linearly as thermal number increased, due to the influence of increasing heat conducted into chip by the side cutting edge. The proposed cutting temperature model was of great significance for both the temperature modeling work of end milling and study of Al-MMCs.

Estimation of Chatter Vibration Under End-Milling Process With a Wavelet Transform

2021 ◽  
Author(s):  
Haruki Minetaka ◽  
Nobutoshi Ozaki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
Fourier Transform ◽  
Wavelet Transform ◽  
End Milling ◽  
Early Stage ◽  
Milling Process ◽  
Frequency Resolution ◽  
Cutting Condition ◽  
Analysis Method ◽  
Chatter Vibration ◽  
Machined Surface

Abstract In this study, a new analysis method using a wavelet transform was considered to evaluate the chatter vibration generated during end milling. End milling often generates vibrations between the tool and work material, called chatter vibration, which causes deterioration of the finished surface and breakage of the tool. Therefore, countermeasures to detect chatter vibration at an early stage have been attempted in the past by using fast Fourier transform (FFT) and short-time Fourier transform (STFT) methods and monitoring the dynamic stability of the cutting process. However, the FFT analysis method assumes steady-state vibration, and the STFT method does not have sufficient frequency resolution. In contrast, the wavelet transform is excellent for analyzing non-stationary vibrations and has a high noise separation capability. To fully validate the analysis method, a groove was added to the machined surface, so that the cutting condition changed with time, and the cutting vibration under the condition where the disturbance was involuntary was analyzed. As a result, it was possible to identify minute fluctuations in chatter vibration, which could not be obtained using the STFT method.

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