scholarly journals Machinability of Rolled Aluminum using Advanced Coated Cutting Tools and its Characterization

2019 ◽  
Vol 8 (3) ◽  
pp. 776-783
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Diamond Tool ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
Constant Depth ◽  
Rolled Aluminum ◽  
Polycrystalline Diamond Inserts

Because of multiple properties like higher values of corrosion resistance, formability, weldability along with greater structural utility aluminum alloys are generally gaining more and more demand in industries and household. With this the requirement for searching of higher quality cutting tool to machine aluminum is also growing. Here different cutting tools like MTCVD+TiCN+Al2O3 , MTCVD+TiCN+Al2O3+TiOCN, MTCVD+TiN+TiCN+Al2O3+TiN, PVD AlTiN, cemented carbide (k-10) insert brazed with Polycrystalline Diamond and Polycrystalline Diamond Inserts are being used to machine rolled aluminum in dry condition and then comparative analysis are made. The cutting is of orthogonal type and capstan lathe is used for the same. Under different conditions of cutting the surface roughness along with morphology of chip are analyzed. Under constant depth of cut (doc) along with variable velocities and feed, the turning operation is performed. With SEM and XRD the identification including characterization of cutting tool were also performed. The polycrystalline diamond tool is found to give optimum surface finish, thin type of chip along with mirror like finish during machining operation.

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.

Optimization of Surface Roughness by Using Different Cutting Tools for Aluminum Alloy 6063

2020 ◽  
Vol 17 (2) ◽  
pp. 961-966
Author(s):  
Allina Abdullah ◽  
Afiqah Azman ◽  
B. M. Khirulrizwan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Optimum Parameter ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Numerical Control ◽  
Depth Of Cut

This research outlines an experimental study to determine the optimum parameter of cutting tool for the best surface roughness (Ra) of Aluminum Alloy (AA) 6063. For the experiment in this research, cutting parameters such as cutting speed, depth of cut and feed rate are used to identify the effect of both cutting tools which are tungsten carbide and cermet towards the surface roughness (Ra) of material AA6063. The machining operation involved to cut the material is turning process by using Computer Numerical Control (CNC) Lathe machine. The experimental design was designed by Full Factorial. The experiment that had been conducted by the researcher is 33 with 2 replications. The total number of the experiments that had been run is 54 runs for each cutting tool. Thus, the total number of experiments for both cutting tools is 108 runs. ANOVA analysis had been analyzed to identify the significant factor that affect the Ra result. The significant factors that affect the Ra result of AA6063 are feed rate and cutting speed. The researcher used main effect plot to determine the factor that most influenced the surface roughness of AA6063, the optimum condition of surface roughness and the optimum parameter of cutting tool. The factor that most influenced the surface roughness of AA6063 is feed rate. The optimum condition of surface roughness is at the feed rate of 0.05 mm/rev, cutting speed of 600 rpm and depth of cut of 0.10 mm. While the optimum parameter of cutting tool is cermet insert with the lowest value of surface roughness (Ra) result which is 0.650 μm.

Study on Wafer Thinning Characteristics of Ultimate Diamond Disk

2012 ◽  
Vol 591-593 ◽  
pp. 476-479
Author(s):  
Xu Xing Jin
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Workpiece Material ◽  
Diamond Disk ◽  
Diamond Cutting Tools ◽  
Wafer Thinning ◽  
Wafer Surfaces

Silicon wafer is machined by diamond cutting tools to certain extent, the cutting tool currently used is polycrystalline diamond (PCD). However, as its cutting edges are not leveled to the same height, it will produce different depth of cut and the stress distribution is uneven on wafer surfaces, in the process of wafer thinning, both the workpiece and the cutting tool are probably damaged, this will increase the production cost accordingly. In this paper, a strategy is described to improve the ability of cutting tool for wafer thinning, a cutting tool named Ultimate Diamond Disk (UDD) designed by Taiwan Wheel Company is recommended, which can reduce both the crack of workpiece and the wear speed of cutting tool. Moreover, an experiment on base of different machining parameters including rotation speed of spindle, feed rate and depth of cut was tested and discussed. As a result, the removal mode of workpiece material and the wafer thinning characteristics of UDD are obtained.

Study on EDM Machining Technics of Polycrystalline Diamond Cutting Tool and PCD Cutting Tool’s Life

2011 ◽  
Vol 268-270 ◽  
pp. 309-315 ◽  
Author(s):  
Yun Hai Jia ◽  
Jian Gang Li ◽  
Xue Jun Lu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Pulse Width ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Machining Parameter ◽  
Diamond Cutting Tool ◽  
The Relationship

The Samples of Polycrystalline Diamond (PCD) Cutting Tool Were Machined by Adjusting the Main Parameters of Electrical Discharge Machining (EDM). after the Machining, the Phases Were Analyzed by X-Ray Diffraction Analyzer and the Surface Layer Microstructure Were Observed by Scanning Electronic Microscope. the Fundamental Component of Machined PCD Cutting Tool Affected Layer Was Obtained and the Reason of Bring Affected Layer Was Analyzed. the Relationship Curves between Pulse Width, Working Electric Current and Depth Affected Layer, Surface Roughness Were Summarized. the Relationship between PCD Cutting Tools that Was Machined by EDM and Cutting Tool Flank Width, Workpiece Surface Roughness Were Analyed.The Results Showed that to Adjust Electical Discharge Machining Parameter, such as Pulse Width and Machining Electric Currents, Can Reduce the Depth of Affect Layer and Extend the Service Life of PCD Cutting Tool.These Researches Provide Valuable Test Reference for Drawing up Electrical Discharge Machining Technics of PCD Cutting Tool and Cutting Tool’s Life.

A Study of the Diamond Tools for Grinding Polycrystalline Diamond

2010 ◽  
Vol 126-128 ◽  
pp. 585-590
Author(s):  
Shenq Yih Luo ◽  
J.K. Ho ◽  
Ming Yi Tsai ◽  
Yi Xian Liu ◽  
William Chen
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
Lower Percentage ◽  
Depth Of Cut ◽  
Workpiece Surface ◽  
Diamond Tools ◽  
Vitrified Bond ◽  
Grinding Efficiency ◽  
Worn Surface

The purpose of this paper was to investigate the grinding performance of two types of cobalt and vitrified bond diamond tools produced by the hot press for the vertical flat grinding polycrystalline diamond. The worn diamond type and the diamond protrusion observed by the toolmaker or SEM after grinding under two different feed rates of 1 and 5 mm/min and the depth of cut of 2 µm with total depth of 10µm were studied. In addition, the grinding efficiency and the workpiece surface roughness produced were analyzed as well. The experiment results showed that when the feed rate of 1 mm/min during the flat grinding PCD was used, a lower percentage of the good diamond, a higher percentage of flat diamond and pulled-out hole on the worn surface of the cobalt bond diamond tool were obtained. For the vitrified bond diamond tool, the good diamond produced showed a higher percentage and flat grit and pulled-out hole displayed a relatively lower percentage. This may be due to the result of the relatively moderate strength and grit retention of the vitrified bond. Furthermore, the diamond protrusion and the grinding efficiency produced for the vitrified bond diamond tool were better than those for the cobalt bond tool. And the PCD surface roughness obtained was better as well.

Effect of lead on the machinability of brass alloys using polycrystalline diamond cutting tools

2018 ◽  
Vol 53 (8) ◽  
pp. 602-615 ◽  
Author(s):  
Luis Amaral ◽  
Rafael Quinta ◽  
Tiago E Silva ◽  
Rui MB Soares ◽  
Santiago D Castellanos ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Chip Morphology ◽  
Lead Free ◽  
Production Techniques ◽  
Polycrystalline Diamond Inserts ◽  
Brass Alloys

The international safety regulations are pushing the manufacturers of water systems and equipment to remove lead from material compositions due to the potential human hazard of lead absorption. The usage of green lead-free brass alloys is becoming mandatory in many important markets, demanding the manufacturers to quickly adapt their production techniques both casting and machining to this new reality. Regarding machining, lead has been used to facilitate the chip control, working as a natural chip breaker and reducing the tool wear. Therefore, the reduction of lead composition in brass alloys contributes to a machinability decrease of the materials leading to higher cutting forces, long chips and higher tool wear. This work focuses on the machinability characterization of three different brass alloys (leaded, medium-leaded and minimally leaded) by means of cylindrical external turning process with polycrystalline diamond inserts. A parametric study covering three different depths of cuts, three feed rates and four cutting speeds was conducted for three brass alloys with two repetitions. Cutting forces, chip morphology and surface roughness were analysed and compared between alloys. Complementary microstructural and mechanical characterization of the alloys were performed. Analysis of variance was performed to analyse the results. Cutting forces, power consumption, specific cutting pressure, roughness and chip morphology identification were used as comparison criteria among the tested materials. Results have demonstrated the decrease of machinability with the lead reduction, with higher cutting forces and longer chips. Polycrystalline diamond tools used in this work could be a good option to overcome the machinability challenges of the lead-free brass alloys.

scholarly journals Study of cutting force and tool wear during turning of aluminium with WC, PCD and HFCVD coated MCD tools

2020 ◽  
Vol 7 ◽  
pp. 27
Author(s):  
Sisira Kanta Pattnaik ◽  
Minaketan Behera ◽  
Sachidananda Padhi ◽  
Pusparaj Dash ◽  
Saroj Kumar Sarangi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Cutting Tools ◽  
Chemical Vapor ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Pcd Tool ◽  
Rolled Aluminum ◽  
Pcd Tools

Enormous developmental work has been made in synthesis of metastable diamond by hot filament chemical vapor deposition (HFCVD) method. In this paper, micro-crystalline diamond (MCD) was deposited on WC–6 wt.% Co cutting tool inserts by HFCVD technique. The MCD coated tool was characterized by the scanning electron microscope (SEM), X-ray diffraction (XRD) and micro Raman spectroscopy (μ-RS). A comparison was made among the MCD tool, uncoated tungsten carbide (WC) tool and polycrystalline diamond (PCD) tool during the dry turning of rolled aluminum. The various major tests were conducted such as surface roughness, cutting force and tool wear, which were taken into consideration to establish a proper comparison among the advanced cutting tools. Surface roughness was measured during machining by Talysurf. The tool wear was studied by SEM after machining. The cutting forces were measured by Kistler 3D-dynamometer during the machining process. The test results indicate that, the CVD coated MCD tool and PCD tool produced almost similar results. But, the price of PCD tools are five times costlier than MCD tools. So, MCD tool would be a better alternative for machining of aluminium.

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

2017 ◽  
Vol 16 (03) ◽  
pp. 237-261 ◽  
Author(s):  
T. Sampath Kumar ◽  
S. Balasivanandha Prabu ◽  
T. Sorna Kumar
Keyword(s):  
Surface Roughness ◽  
Alloy Steel ◽  
Surface Finish ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Coated Carbide

In the present work, the performances of TiAlN-, AlCrN- and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN- and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi’s approach is used to obtain the best turning parameters, namely cutting speed ([Formula: see text]), feed rate ([Formula: see text]) and depth of cut ([Formula: see text]), in order to have a better surface finish and minimum tool flank wear. An orthogonal array (L[Formula: see text] was used to conduct the experiments. The results show that the AlCrN/TiAlN-coated cutting tool provided a much better surface finish and minimum tool flank wear. The minimum tool flank wear and minimum surface roughness were obtained using AlCrN/TiAlN-coated tools, when [Formula: see text][Formula: see text]m/min, [Formula: see text][Formula: see text]mm/rev and [Formula: see text][Formula: see text]mm.

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.

scholarly journals Remaining Useful Life Prediction of Cutting Tools Using an Inverse Gaussian Process Model

2021 ◽  
Vol 11 (11) ◽  
pp. 5011
Author(s):  
Yuanxing Huang ◽  
Zhiyuan Lu ◽  
Wei Dai ◽  
Weifang Zhang ◽  
Bin Wang
Keyword(s):  
Surface Roughness ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Remaining Useful Life ◽  
Model Parameters ◽  
Inverse Gaussian ◽  
Wear Process ◽  
Useful Life ◽  
Dynamic Wear

In manufacturing, cutting tools gradually wear out during the cutting process and decrease in cutting precision. A cutting tool has to be replaced if its degradation exceeds a certain threshold, which is determined by the required cutting precision. To effectively schedule production and maintenance actions, it is vital to model the wear process of cutting tools and predict their remaining useful life (RUL). However, it is difficult to determine the RUL of cutting tools with cutting precision as a failure criterion, as cutting precision is not directly measurable. This paper proposed a RUL prediction method for a cutting tool, developed based on a degradation model, with the roughness of the cutting surface as a failure criterion. The surface roughness was linked to the wearing process of a cutting tool through a random threshold, and accounts for the impact of the dynamic working environment and variable materials of working pieces. The wear process is modeled using a random-effects inverse Gaussian (IG) process. The degradation rate is assumed to be unit-specific, considering the dynamic wear mechanism and a heterogeneous population. To adaptively update the model parameters for online RUL prediction, an expectation–maximization (EM) algorithm has been developed. The proposed method is illustrated using an example study. The experiments were performed on specimens of 7109 aluminum alloy by milling in the normalized state. The results reveal that the proposed method effectively evaluates the RUL of cutting tools according to the specified surface roughness, therefore improving cutting quality and efficiency.

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