Zerspanung von Gusseisen mit PKD-Schneidstoffen*/Compacted graphite iron machining with PCD cutting inserts - Impact of material alloy and technological parameters on the performance of PCD tools

2016 ◽  
Vol 106 (01-02) ◽  
pp. 21-26
Author(s):  
E. Abele ◽  
T. Heep
Keyword(s):  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Compacted Graphite Iron ◽  
Technological Parameters ◽  
Compacted Graphite ◽  
Automotive Engines ◽  
Diamond Cutting Tools ◽  
Cutting Inserts ◽  
Pcd Tools ◽  
The Impact

Im Motorenbau werden vermehrt hochfeste Vermiculargusswerkstoffe mit hervorragenden mechanischen Eigenschaften eingesetzt. Die Zerspanbarkeit von Gusseisen mit Vermiculargrafit (GJV) stellt jedoch eine große Herausforderung dar. Die nachfolgenden Untersuchungsergebnisse verdeutlichen die Auswirkungen der Werkstoffcharge und der technologischen Randbedingungen auf das Einsatzverhalten von polykristallinen Diamantschneidstoffen.   Higher strength cast iron materials with improved mechanical properties are used for the construction of automotive engines. Especially machining of compacted graphite iron (CGI) is challenging for the manufacturer. This paper deals with the impact of different material batches in case of CGI-450 and with the effect of varied technological boundary conditions on tool life of polycrystalline diamond cutting tools.

Drehen von Vermicularguss unter kryogener Kühlung*/Turning compacted graphite iron under cryogenic cooling - Studies on the impact of process cooling on material and chip formation properties

2017 ◽  
Vol 107 (01-02) ◽  
pp. 14-20
Author(s):  
M. Prof. Oechsner ◽  
M. Siebers ◽  
H. Scheerer ◽  
G. Andersohn ◽  
E. Prof. Abele ◽  
...  
Keyword(s):  
Chip Formation ◽  
Cutting Tools ◽  
Construction Materials ◽  
Cryogenic Cooling ◽  
Compacted Graphite Iron ◽  
Compacted Graphite ◽  
Cutting Energy ◽  
Automotive Powertrain ◽  
Technological Constraints ◽  
The Impact

Vermiculargusswerkstoffe zählen zu vergleichsweise schwer zerspanbaren Werkstoffen im automobilen Antriebsstrang. Insbesondere kontinuierliche Schnittbedingungen stellen hohe Anforderungen an die eingesetzten Schneidstoffe. Kryogene Kühlverfahren können einen entscheidenden Beitrag zur Verlängerung der Werkzeugstandzeit von Hartmetall- und diamantbasierten Schneidstoffen leisten. Der Fachbeitrag fasst die Untersuchungen zum Einfluss der Prozesskühlung auf die Werkstoff- und Spanbildungseigenschaften zusammen.   Compacted graphite iron (CGI-450) with its excellent mechanical properties has a large and still increasing importance in the field of construction materials, especially in the field of automotive powertrain applications. The choice of tungsten carbide and diamond-based cutting tools with suitable technological constraints and different cooling strategies in view of chip formation, chip shape and cutting energy are to be illustrated in the following tests.

Wear Model in Milling Compacted Graphite Iron with Different Lead Angle Using Ceramic Cutting Tools

2013 ◽  
Vol 199 ◽  
pp. 371-376 ◽  
Author(s):  
Şener Karabulut ◽  
Abdulkadir Güllü
Keyword(s):  
Cutting Tools ◽  
Depth Of Cut ◽  
Compacted Graphite Iron ◽  
Ann Model ◽  
Wear Model ◽  
Workpiece Material ◽  
Angle Variation ◽  
Compacted Graphite ◽  
Lead Angle ◽  
Cutting Inserts

The objective of this study is to reveal the influence of the lead angle variation on tool wear in the process of face milling of compacted graphite iron with ceramic cutting tools. To achieve this goal, 36 milling experiments were carried out with different lead angles, cutting speeds and feed rates at the 2.5 mm constant depth of cut. The tool flank wear was strongly affected by the lead angle variations. SEM analyses of the cutting inserts were performed and experimental results have been modelled with artificial neural networks (ANN) and regression analysis. A comparison of ANN model with regression model is also carried out. The R2 values for testing data were calculated as 0.992 for ANN and 0.998 for regression respectively. This study is considered to be helpful in predicting the wear mechanism of the ceramic cutting tool in the machining of compacted graphite iron. A quicker method for the estimation of tool life is proposed, which requires less consumption of workpiece material and tools.

Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

2007 ◽  
Author(s):  
Niniza S. P. Dlamini ◽  
Iakovos Sigalas ◽  
Andreas Koursaris
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Crater Wear ◽  
Compacted Graphite ◽  
Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

scholarly journals The Role of Thin-Film Vacuum-Plasma Coatings and Their Influence on the Efficiency of Ceramic Cutting Inserts

Coatings ◽  
2018 ◽  
Vol 8 (8) ◽  
pp. 287 ◽  
Author(s):  
Marina Volosova ◽  
Sergey Grigoriev ◽  
Alexander Metel ◽  
Alexander Shein
Keyword(s):  
Bending Strength ◽  
Surface Defects ◽  
Cutting Tools ◽  
High Energy ◽  
Radius Of Curvature ◽  
Sic Ceramic ◽  
Operational Tests ◽  
Mechanical Fastening ◽  
Cutting Inserts ◽  
The Impact

The main problem with ceramics used in cutting tools is related to the unpredictable failures caused by the brittle fracturing of ceramic inserts, which is critical for the intermittent milling of cyclic loading. A 125-mm-diameter eight-toothed end mill, with a mechanical fastening of ceramic inserts, was used as a cutting tool for milling hardened steel (102Cr6). For the experiments, square inserts of the Al2O3 + SiC ceramic were used and compared with the samples made of Al2O3 + TiC to confirm the obtained results. The samples were coated with diamond-like coating (DLC), TiZrN, and TiCrAlN coatings, and their bending strength and adhesion were investigated. Investigations into the friction coefficient of the samples and operational tests were also carried out. The effect of smoothing the microroughness and surface defects in comparison with uncoated inserts, which are characteristic of the abrasive processing of ceramics, was investigated and analyzed. The process developed by the authors of the coating process allows for the cleaning and activation of the surface of ceramic inserts using high-energy gas atoms. The impact of these particles on the cutting edge of the insert ensures its sharpening and reduces the radius of curvature of its cutting edges.

Scribing Characteristics of Glass Plate with Ground PCD Scribing Wheel

2018 ◽  
Vol 12 (5) ◽  
pp. 760-766
Author(s):  
Yusuke Akiyama ◽  
Mutsumi Okada ◽  
Hirofumi Suzuki ◽  
Toshio Fukunishi ◽  
Yoshiyuki Asai ◽  
...  
Keyword(s):  
High Efficiency ◽  
Glass Plate ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Diamond Wheel ◽  
Precision Machining ◽  
Electric Discharge Machining ◽  
Single Crystal Diamond ◽  
Pcd Tools ◽  
Alloy Metal

Polycrystalline diamond (PCD) tools are widely used for cutting tools because PCD has no crystal orientation and is an isotropic material, it is low in cost, and it is easily machined by electric discharge machining. PCD is sintered from diamond abrasives with an alloy metal, such as cobalt, and it is difficult to reduce the surface roughness and the edge accuracy compared with single crystal diamond. In this study, high efficiency and high precision machining of the PCD wheel were investigated. In the experiments, PCD wheels were ground with a diamond wheel, and the effects of the grinding direction and the load on the tool preciseness and the scribing performance were examined.

scholarly journals The Impact Of Surface Shape Of Chip-Breaker On Machined Surface

2015 ◽  
Vol 12 (2) ◽  
pp. 24-27
Author(s):  
Michal Šajgalík ◽  
Andrej Czán ◽  
Juraj Martinček ◽  
Daniel Varga ◽  
Pavel Hemžský ◽  
...  
Keyword(s):  
Automotive Industry ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Surface Shape ◽  
Technological Parameters ◽  
Machined Surface ◽  
Chip Breaker ◽  
Cutting Insert ◽  
Chip Size ◽  
The Impact

Abstract Machined surface is one of the most used indicators of workpiece quality. But machined surface is influenced by several factors such as cutting parameters, cutting material, shape of cutting tool or cutting insert, micro-structure of machined material and other known as technological parameters. By improving of these parameters, we can improve machined surface. In the machining, there is important to identify the characteristics of main product of these processes – workpiece, but also the byproduct - the chip. Size and shape of chip has impact on lifetime of cutting tools and its inappropriate form can influence the machine functionality and lifetime, too. This article deals with elimination of long chip created when machining of shaft in automotive industry and with impact of shape of chip-breaker on shape of chip in various cutting conditions based on production requirements.

Additive Fertigung keramischer Schneidstoffe/Additive manufacturing of ceramic cutting materials. Production of indexable inserts for turning using the LCM process

2020 ◽  
Vol 110 (01-02) ◽  
pp. 2-6
Author(s):  
Matthias Weigold ◽  
Timo Scherer ◽  
Eric Schmidt ◽  
Martin Schwentenwein ◽  
Thomas Prochaska
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Additive Fertigung ◽  
Compacted Graphite ◽  
Ceramic Components ◽  
Ceramic Manufacturing ◽  
Longitudinal Turning

Die additive Fertigung von Schneidstoffen hat das Potenzial, leistungsfähigere Zerspanungswerkzeuge zu ermöglichen. Das Lithography-based Ceramic-Manufacturing-(LCM)-Verfahren erlaubt die Fertigung hochbelastbarer Bauteile aus Keramik. Dieser Beitrag stellt zum einen das LCM-Verfahren und zum anderen die Entwicklung additiv herstellbarer Wendeschneidplatten vor. Zuletzt erfolgt die Überprüfung der Funktionstauglichkeit von additiv hergestellten keramischen Wendeschneidplatten in Außenlängsdrehversuchen mit vermicularem Gusseisen (GJV-450).   The additive manufacturing of cutting materials has the potential to enable more efficient cutting tools. The Lithography-based Ceramic Manufacturing (LCM) process allows for the production of high-performance ceramic components. This article presents the LCM process as well as the development of indexable inserts that can be produced additively. Finally, the results of external longitudinal turning tests in Compacted Graphite Iron (CGI-450) are presented.

Thinning Silicon Wafer with Polycrystalline Diamond Tools

2009 ◽  
Vol 404 ◽  
pp. 157-163
Author(s):  
Pei Lum Tso ◽  
Cheng Huan Chen
Keyword(s):  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Wafer Surface ◽  
Depth Of Cut ◽  
Entire Surface ◽  
Machined Surface ◽  
Drill Bits ◽  
Ductile Mode ◽  
Critical Depth Of Cut ◽  
Pcd Tools

Sintered polycrystalline diamond (PCD) compacts are normally used for cutting tools, drill bits and wire dies. A novel application of PCD has been developed to use its entire surface carved to create different patterns which are triangle or square shape loaded with leveled millers that can shave brittle materials in ductile mode. Due to numerous cutting edges formed on the same level of PCD tools, which can be used to thin the wafer surface to achieve both flatness and smoothness of the industrial requirements. SEM has been used to observe the surface and subsurface of the thinned wafer surface. The critical depth of cut between ductile and brittle cutting mode is close to 2 µm in this thinning operation. The damaged layers of machined surface have been observed and studied in this paper.

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.

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