scholarly journals Tool Wear Analysis During Turning of Hard Material by Simulink

2019 ◽  
Vol 8 (5S3) ◽  
pp. 28-31
Keyword(s):  
Tool Wear ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Tool Material ◽  
Bearing Steel ◽  
Hard Material ◽  
Simulink Model ◽  
Wear Analysis ◽  
Diffusion Wear ◽  
Total Wear

Present work is an attempt to develop a simulink model of tool wear by machining of Bearing Steel (62 HRC) using cubic boron nitride (CBN) tool. The available mathematical model in the scholarly literature is used to make the simulation model using MATLAB software. Three components of tool wear adhesive wear, abrasive wear & diffusion wear are considered separately for their modeling and later modeling of total wear is done. Variation of tool wear is studied with respect to cutting speed. The developed simulink model is capable to do the similar type of study by changing the workpiece and tool material combination.

Evaluation of Thermal Effects in Turning Processes: Numerical and Experimental Approach

2019 ◽  
Author(s):  
Aruna Prabha Kolluri ◽  
Srinivasa Prasad Balla ◽  
Satya Prasad Paruchuru
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Tool Material ◽  
Maximum Error ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Abstract The 3D Finite element method (FEM) is an efficient tool to predict the variables in the cutting process, which is otherwise challenging to obtain with the experimental methods alone. The present study combines both experimental findings and finite element simulation outcomes to investigate the effect of tool material on output process variables, such as vibrations, cutting temperature distribution and tool wear mechanism. Machining of popular aerospace materials like Ti-6Al-4V and Al7075 turned with coated and uncoated tools are part of the investigation. The authors choose the orthogonal test, measured vibrations and cutting temperatures and used FE simulations to carry out the subsequent validations. This study includes the influence of the predicted heat flux and temperature distribution on the tool wear mechanism. The main aim of this study is to investigate the performance quality of uncoated and coated carbide tools along with its thermal aspects. Comparison of experiment and simulation outcomes shows good agreement with a maximum error of 9.02%. It has been noted that the increase of cutting temperature is proportional to its cutting speed. As the cutting speed increases, it is observed that vibration parameter and flank wear value also increases. Overall, coated carbide turning insert tool is the best method for metal turning with higher rotational speeds of the spindle.

Tool Wear of Polycrystalline Cubic Boron Nitride Compact Tools in Cutting Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 724-728 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Boron Nitride ◽  
Tool Wear ◽  
Tool Life ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Cbn Tool ◽  
High Cutting Speed

Using polycrystalline cubic boron nitride compact (cBN) tools, which have different cBN contents and cBN particle sizes, the influences of both the cBN content and the cBN particle size on tool wear in turning of hardened steel at various cutting speeds was experimentally investigated. Three types of cBN tools (a cBN content of 45-55% and 75%, and a cBN particle size of 0.5 μm and 5 μm, respectively) were tested. Furthermore, three kinds of chamfered and honed cutting edges were also used. The main results obtained are as follows: (1) In the case of the cBN tools with the same cBN particle size of 5.0 μm, the tool life of the cBN tool with a cBN content of 75% was longer than that of the cBN tool with a cBN content of 45% at low cutting speed. However, at high cutting speed, the tool life of the cBN tool with a cBN content of 75% was shorter. (2) The tool life of the cBN tool with both a cBN content of 55% and a cBN particle size of 0.5 μm was the longest. (3) The tool wear of cBN tools decreased with a decrease in chamfer width.

Machinability of Pearlitic Cast Iron With Cubic Boron Nitride (CBN) Cutting Tools

2002 ◽  
Vol 124 (4) ◽  
pp. 820-832 ◽  
Author(s):  
Jiancheng Liu ◽  
Kazuo Yamazaki ◽  
Hiroyuki Ueda ◽  
Norihiko Narutaki ◽  
Yasuo Yamane
Keyword(s):  
Cast Iron ◽  
Boron Nitride ◽  
Tool Wear ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Conditions ◽  
Machining Center

In order to increase the accurate finishing productivity of pearlitic cast iron, face milling by CBN (Cubic Boron Nitride) cutting tools was studied. The main focus of the study is the machinability investigation of pearlitic cast iron with CBN cutting tools by studying the relationships among machining conditions such as feed rate, cutting speed as well as CBN cutting tool type, tool wear, workpiece surface quality, cutting forces, and cutting temperature. In addition, an emphasis is put on the effect of Al additive in pearlitic cast iron on its machinability and tool wear characteristics. High-speed milling experiments with CBN cutting tools were conducted on a vertical machining center under different machining conditions. The results obtained provide a useful understanding of milling performance by CBN cutting tools.

Application of CBN Cutting Tools in Hard Turning and Tool Wear

2013 ◽  
Vol 690-693 ◽  
pp. 2022-2025
Author(s):  
Hai Dong Zhao ◽  
Li Bao An ◽  
Pei Qing Yang ◽  
Ye Geng
Keyword(s):  
Tool Wear ◽  
Hard Turning ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Elevated Temperatures ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Tool Material ◽  
Specific Strength ◽  
Strength And Stiffness

Considerable research has been directed towards discovering new engineering materials for various applications. As a superhard material, Cubic Boron Nitride (CBN) has been developed and applied to engineering for several tens of years. Due to its high specific strength and stiffness as well as good creep, fatigue and wear resistance at elevated temperatures, CBN has been widely used as cutting tool material in manufacturing industry. In this paper, the preparation and characteristics of CBN are introduced. As hard turning has been more and more employed in recent years as an advanced metal cutting technique, the application of CBN cutting tools in hard turning is presented based on the literature, and in particular, the main wear mechanisms of CBN tools in hard turning are summarized, owing to the significant influence of tool wear on the tool life and product quality.

Study on Wear Mechanism of Carbide Tool in Machining Inconel 718

2013 ◽  
Vol 589-590 ◽  
pp. 323-326 ◽  
Author(s):  
Yi Hang Fan ◽  
Liang Zhou ◽  
Shuang Zhu Song ◽  
Feng Lian Sun
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Wear Debris ◽  
Oxidation Reaction ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Tool Breakage ◽  
Nickel Based Superalloy ◽  
Cemented Carbide Tools

Tool wear is a problem in machining nickel-based superalloy Inconel 718, and it is thus of great importance to understand and quantitatively predict tool wear. The experiments of machining Inconel 718 with cemented carbide tools (uncoated and coated) were carried out. Some new observations and analysis of tool wear through CCD, SEM and EDS were done. The results showed that at low cutting speed, the built up edge (BUE) formed easily and dropped at last which caused severe cutting tool breakage. When cutting speed came to 30m/min, the main reason that caused cutting tool wear was that the tool material fell off from the tool body at the form of wear debris. What’s more, the element diffusion between tool and workpiece and oxidation reaction all accelerate the formation and the cast of the wear debris.

High speed turning for hard material with PCBN inserts: tool wear analysis

2008 ◽  
Vol 3 (1/2) ◽  
pp. 62 ◽  
Author(s):  
Farouk Mahfoudi ◽  
Gautier List ◽  
Alain Molinari ◽  
Abdelhadi Moufki ◽  
Lakhdar Boulanouar
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Hard Material ◽  
High Speed Turning ◽  
Wear Analysis

Tool Wear of PVD Coated Carbide Tool when Finish Turning Inconel 718 under High Speed Machining

2010 ◽  
Vol 129-131 ◽  
pp. 1004-1008 ◽  
Author(s):  
M.Z.A. Yazid ◽  
C.H. Che Hassan ◽  
A.G. Jaharah ◽  
A.I. Gusri ◽  
M.S. Ahmad Yasir
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Nose Radius ◽  
Machining Processes ◽  
Finish Turning ◽  
Diffusion Wear ◽  
Flank Face ◽  
Coated Carbide

This paper reports the results of an experimental works, where Inconel 718, a highly corrosive resistant, nickel-based super alloy, was finish-turning under high speed conditions. The machining processes were carried out at three different cutting conditions (DRY, MQL 50 ml/h and MQL 100 ml/h), three levels of cutting speed (Vc=90, 120 and 150 m/min), two levels of feed rate (f=0.10 and 0.15 mm/rev) and two levels of cutting depth (d=0.30 and 0.50 mm). The tool wear and flank wear progression were monitored, measured and recorded progressively at various time intervals. The experiments indicated that MQL condition performs better than dry condition in term of tool life. Most of the tool failures during machining were due to gradual failure where abrasive and notching wear on the flank face was the dominant followed by, fracture on the flank edge and nose radius. Tool failure due to crater wear was not significant. Wear mechanism such as abrasive and adhesion were observed on the flank face and diffusion wear was observed on the rake face.

Technical Resource of the Cutting Wedge is the Foundation of the Machining Regime Determination

2020 ◽  
Vol 10 (2) ◽  
pp. 1-17 ◽  
Author(s):  
Viktor P. Astakhov ◽  
Stanislav V. Shvets
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Tool Wear ◽  
Work Done ◽  
Cutting System ◽  
Small Tool

This article argues that cutting tool wear is not just a particular case of wear found in general machinery because the whole amount of energy required for cutting is transmitted through relatively small tool-chip and tool-workpiece interfaces causing extremely high contact temperatures and pressures. This article discusses a considerably different approach to the determination of the cutting speed based upon the energy passing through the cutting wedge. Moreover, it discusses that, for a given tool material/geometry, there is a limited amount of such energy that the cutting wedge can sustain before reaching the criterion of tool life. This limit is considered as the technical resource of the cutting tool. The article establishes and verifies the existence of the detect correlation between the works done in the cutting system and in tool wear. Based on this finding, the equations to calculate the cutting speed for a chosen tool life and/or the tool life for a chosen cutting speed are proposed. The concept of the technical resource of the cutting wedge is introduced as the total amount of work done before it fails.

Dry turning of AISI D3 steel using a mixed ceramic insert: A study

2019 ◽  
Vol 233 (19-20) ◽  
pp. 6698-6712 ◽  
Author(s):  
D Rath ◽  
S Panda ◽  
K Pal
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Hard Material ◽  
Mixed Ceramic ◽  
Aisi D3 Steel ◽  
Ceramic Insert

AISI D3 steel is a new kind of hardened tool steel with excellent wear resistance. This hard material receives wide promotion, investigation, and application in the die manufacturing industries. In the machining of AISI D3 steel, tool wear has a close relationship with the presence of different constituent elements in the workpiece material and cutting conditions. This study reports an improved experimental investigation approach to the analysis of effect of cutting speed, feed rate, and depth of cut on cutting forces, surface roughness, tool wear, and chip morphology in high-speed turning of AISI D3 steel using a hybrid TiN-coated Al2O3 + TiCN mixed ceramic insert. The range of each parameter is set at different levels for the analysis purpose. The experimental observations show that the cutting force is predominantly influenced by the feed rate accompanied by the depth of cut. The predominant factor influencing flank wear is the feed rate accompanied by the depth of cut and cutting speed. Feed rate is one of the dominating factors that influences the surface finish characteristics. The characterization of tool wear and chip morphology was performed by a scanning electron microscope supplied with energy-dispersive X-ray spectroscopy pattern. The results demonstrated that the predominant wear mechanism of the multilayered hybrid-coated tool was flank wear, crater wear, adhesion wear, and abrasive wear.

Achieving Optimal Process Parameters during Hard Turning of AISI 52100 Bearing Steel Using Hybrid GRA-PCA

2019 ◽  
Vol 818 ◽  
pp. 87-91 ◽  
Author(s):  
P. Umamaheswarrao ◽  
D. Ranga Raju ◽  
K.N.S. Suman ◽  
B. Ravi Sankar
Keyword(s):  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 52100 ◽  
Input Parameters

In the present work hard turning of AISI 52100 steel has been performed using Polycrystalline cubic boron nitride (PCBN) tools. The input parameters considered are cutting speed, feed, depth of cut, nose radius and negative rake angle and the measured responses are machining force and workpiece surface temperature. Experiments are planned as per Central Composite Design (CCD) of Response Surface Methodology (RSM). The effect of input parameters and their interactions are discussed with main effects plot. Further, the multi-objective optimization scheme is proposed by adopting Grey Relational Analysis (GRA) coupled with Principle Component Analysis (PCA). Results demonstrated that speed is the most significant factor affecting the responses followed by negative rake angle, feed, depth of cut, and nose radius. The optimum cutting parameters obtained are cutting speed 1000 rpm, feed 0.02 mm/rev, depth of cut 0.5 mm, Nose radius 1 mm and Negative rake angle 5o.

Sign in / Sign up

Export Citation Format

Share Document