Hardening effect on machined surface for precise hard cutting process with consideration of tool wear

2014 ◽  
Vol 27 (6) ◽  
pp. 1249-1256 ◽  
Author(s):  
Caixu Yue ◽  
Xianli Liu ◽  
Jing Ma ◽  
Zhaojing Liu ◽  
Fei Liu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Process ◽  
Machined Surface ◽  
Hardening Effect ◽  
Hard Cutting

2D FEM Estimate of Tool Wear in Hard Cutting Operation: Tool Wear and Simulation of Hard Cutting Process under Steady State

2009 ◽  
Vol 69-70 ◽  
pp. 306-310
Author(s):  
Fu Gang Yan ◽  
Cai Xu Yue ◽  
Xian Li Liu ◽  
Yu Fu Li ◽  
Shu Yi Ji
Keyword(s):  
Steady State ◽  
Tool Wear ◽  
Model Simulation ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Workpiece Material ◽  
Machined Surface ◽  
Fem Model ◽  
Fem Method ◽  
Hard Cutting

Tool wear plays an important role in cutting process research. It affects the quality of machined surface and cutting parameter to a great extent, such as cutting force, cutting temperature and cutting quiver. In order to predict tool wear in hard cutting process by using FEM method, the character of tool wear during cutting process is presented firstly, and Usui’s tool wear rate model is introduced. Then the FEM model for steady state cutting process using Abaqus is established. FEM model describes the workpiece material characteristic accurately for the process of PCBN tool cutting GCr15 by adoptiving Johnson-Cook constitutive model. Simulation results of steady cutting process offer foundation to simulate tool wear.

2D FEM Estimate of Tool Wear in Hard Cutting Operation: Extractive of Interrelated Parameters and Tool Wear Simulation Result

2009 ◽  
Vol 69-70 ◽  
pp. 316-321 ◽  
Author(s):  
Cai Xu Yue ◽  
Xian Li Liu ◽  
Hong Min Pen ◽  
Jing Shu Hu ◽  
Xing Fa Zhao
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Wear Loss ◽  
Cutting Condition ◽  
Machined Surface ◽  
Wear Prediction ◽  
Tool Wear Prediction ◽  
Cutting Model ◽  
Hard Cutting

Tool wear plays an important part during cutting process, and wear loss has a close relationship with cutting condition, which affects machined surface mostly. In order to accomplish tool wear prediction in way of FEM, based on founding of cutting model under steady state, interrelated parameters needed for tool wear prediction, such as cutting temperature, contact pressure and raletive sliding velocity are extracted. By compiling Python subprogram and using Abaqus tool in hard cutting process PCBN tool wear is predicted, which provide foundation for optimizing cutting condition.

Ultraprecision Ductile-Regime Cutting of Optical Glass

2007 ◽  
Vol 364-366 ◽  
pp. 69-73 ◽  
Author(s):  
Ming Zhou ◽  
Ying Chun Liang ◽  
Shao Nan Huang
Keyword(s):  
Tool Wear ◽  
Optical Glass ◽  
Cutting Process ◽  
Process Conditions ◽  
Diamond Cutting ◽  
Machined Surface ◽  
Vibration Cutting ◽  
Tool Wear Mechanism ◽  
Cutting Zone ◽  
Zone Microstructure

Nano-indentation of glass SF11 was performed for understanding the material deformation behavior in practical cutting process. Diamond cutting tests under different process conditions, i.e. conventional turning and ultrasonic vibration assisted cutting, were also carried out. Cleavage and microchipping appear to be the dominant tool wear mechanism based on the analytical results of wear zone microstructure and machined surface topography. The change in the tribology of the cutting process as well as the alteration of the deformation mechanism of the work material in the cutting zone might be responsible for the reduction in tool wear in vibration cutting.

scholarly journals Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4664
Author(s):  
Yao Sun ◽  
Liya Jin ◽  
Yadong Gong ◽  
Yang Qi ◽  
Huan Zhang ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Tool Wear ◽  
Rear Surface ◽  
Cutting Process ◽  
Cutting Fluid ◽  
Machined Surface ◽  
Micro Cutting ◽  
Cutting Surface ◽  
Alloy Material ◽  
End Mills

Aluminum alloy material is widely used in the electronics, weapons, aviation and aerospace industries, due to its medium strength, good corrosion resistance, good toughness and excellent oxidation properties. With the trend of product miniaturization, micro cutting has become the mainstream technique for fabricating micro parts and components, so it is very meaningful and vital to work on removing the cutting fluid from the micro cutting process and make it totally sustainable and eco-friendly. In this work, an attempt has been made to fabricate micro textures onto the rear surface of helical micro end mills with diameters of less than 1 mm. Micro textures in the form of grooves were fabricated using a noncontact low speed wire electrical discharge turning technique. Dry micro cutting experiments were carried out on an aluminum alloy material using helical micro end mills with micro textures and the dry micro cutting surface quality and tool wear have been investigated. The influence of dry micro cutting parameters on the surface roughness parameters were also investigated. Experimental results showed that the Sa and Sq can be reduced to be about 1.56 μm and 2.08 μm, respectively. Contrasting results indicate that the implantation of micro textures does not deteriorate the dry micro cutting surface but improves the machined surface consistency of an aluminum alloy workpiece. The tool wear on helical micro end mills with micro textures involved in the dry micro cutting process of Al 6061 mainly include rear frictional wear, oxidation wear and diffusion wear.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Modeling of Cutting Process with Cutter Axis Inclination

2011 ◽  
Vol 223 ◽  
pp. 66-74 ◽  
Author(s):  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Mechanistic Models ◽  
End Mill ◽  
High Quality ◽  
Ball End Mill ◽  
Milling Operations ◽  
Edge Roughness

Multi-axis controlled machining has been increasing with the demand for high quality in mold manufacturing. The cutter axis inclination should be properly determined in the milling operations. The paper discusses the cutting process of ball end mill with the cutter axis inclination. Two mechanistic models are presented to show the effect of the cutter axis inclination on the tool wear and the surface finish. The actual cutting time during a rotation of the cutter reduces with increasing the cutter axis inclination. Then, the tool is cooled in the non-cutting time. The tool wear is suppressed with reducing the cutting temperature. The surface finish is also improved by increasing cutting velocities with the cutter axis inclination. When the cutter is inclined in the feed direction, the effect of the edge roughness on the surface finish is eliminated. The discussion based on the simulation is verified in the cutting tests for brittle materials.

Analysis of Sound Signal Generation Due to Flank Wear in Turning

2000 ◽  
Author(s):  
Ming-Chyuan Lu ◽  
Elijah Kannatey-Asibu
Keyword(s):  
Tool Wear ◽  
Manufacturing Systems ◽  
Cutting Process ◽  
Reconfigurable Manufacturing ◽  
Monitoring Tool ◽  
Major Step ◽  
Part Quality ◽  
Audible Sound ◽  
The Individual ◽  
Flank Surface

Abstract Ramp-up is a major step in the implementation of manufacturing systems, and is even more critical in reconfigurable manufacturing systems. For a successful reduction in ramp-up time, it is essential to analyze and monitor both the overall manufacturing system and the individual machine tools/processes that comprise the system. Towards this end, we have addressed the issue of monitoring tool wear using audible sound to enable faulty conditions associated with wear to be identified during the process before the part quality gets out of specification. Audible sound generated from the cutting process is analyzed as a source for monitoring tool wear during turning, assuming adhesive wear as the predominant wear mechanism. The analysis incorporates the dynamics of the cutting process. In modeling the interaction on the flank surface, the asperities on the surfaces are represented as a trapezoidal series function with normal distribution. The effect of changing asperity height, size, spacing, and the stiffness of the asperity interaction is investigated and compared with experimental data.

COMPARISON OF PREPARATION METHODS IN TERMS OF TOOL LIFE AND SURFACE ROUGHNESS

2021 ◽  
Vol 2021 (4) ◽  
pp. 4836-4840
Author(s):  
ROBERT STRAKA ◽  
◽  
JOZEF PETERKA ◽  
TOMAS VOPAT ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Parameters ◽  
Turning Process ◽  
Machined Surface ◽  
Preparation Methods ◽  
Machined Surface Roughness ◽  
Cutting Inserts ◽  
Drag Finishing ◽  
Edge Preparation

The article compares two cutting edge preparation methods and their influence on the machined surface roughness of the difficult to cut nickel alloy Inconel 718 and the tool wear of cutting inserts made of cemented carbide. The manufacturing and preparation process of cutting inserts used in the experiment were made by Dormer Pramet. The preparation methods used in the experiment were drag finishing and brushing. Cutting parameters did not change during the whole turning process to maintain the same conditions in each step of the process and were determined based on tests for a semi-finishing operation of the turning process. To obtain durability of 25 to 30 minutes with controlled development of the tool wear the cutting parameters were determined with cooperation with the cutting inserts manufacturer.

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