Finite Element Analysis of Tool Wear in Hot Machining Process

2019 ◽  
pp. 232-248
Author(s):  
Asit Kumar Parida
Keyword(s):  
Tool Wear ◽  
Room Temperature ◽  
Heating Temperature ◽  
Chip Morphology ◽  
High Hardness ◽  
Tool Temperature ◽  
Element Analysis ◽  
Hot Machining ◽  
Wear And Corrosion Resistance ◽  
Wear Tool

Super alloys have been used widely in all sectors (e.g., automobile, aerospace, biomedical, etc.) for their properties like high hardness, high wear, and corrosion resistance. A central challenge is the significantly higher temperature and pressure on the cutting tool, hence rapid tool wear and bad surface finish. In the present study, a FEM analysis has been developed to calculate the effect of preheating temperature on the surface of the workpiece on tool wear on machining Inconel 718. Usui's tool wear model has been implemented in DEFORM software. In order to validate the results, an experimental investigation has been carried out with same cutting conditions. The evaluated results were also compared with the room temperature machining condition. It was observed that the heating temperature increased the tool life by reducing tool wear, tool temperature compared to room temperature machining condition. The predicted tool wear, tool temperature, and chip morphology have been compared with the experimental results and good correlation was found.

A Study on the High Speed Face Milling of Ti-6Al-4V Alloy

Manufacturing ◽  
2002 ◽  
Author(s):  
Balkrishna Rao ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Experimental Analysis ◽  
High Speed ◽  
Numerical Study ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Face Milling ◽  
Machined Surface ◽  
Element Analysis

This paper is concerned with the experimental and numerical study of the high speed face milling of Ti-6Al-4V titanium alloy. Machining is carried out by uncoated carbide and polycrystalline diamond cutters in the presence of an abundant supply of coolant. Experimental analysis is conducted in terms of cutting forces, chip morphology, surface integrity and tool wear. The experimental analysis is supplemented by simulations from the finite element analysis where needed. The highest cutting speed realized for both the cutting tool materials is 600 sfpm with the diamond cutter operating at feeds lower than that for carbide. Good surface integrity in terms of residual stress and surface finish is achieved under the machining conditions used with limited tool wear. Residual stresses imparted to the machined surface are compressive with the diamond tool yielding higher values and are the most sensitive to feed. Tool wear patterns are described in terms of various cutting conditions.

scholarly journals Performance Testing and Strength Prediction of Ceramic-to-Metal Joints

1993 ◽  
Author(s):  
J. H. Selverian ◽  
Dave A. ONeil ◽  
Shinhoo Kang
Keyword(s):  
Room Temperature ◽  
Performance Testing ◽  
Strength Prediction ◽  
High Temperature Strength ◽  
Torsional Loading ◽  
Element Analysis ◽  
Failure Theory ◽  
Brazed Joints ◽  
Temperature Shear ◽  
Shrink Fit

Brazed joints were made between silicon nitride and Ni-based and Fe-based super alloys. Room temperature shear (torsion) strengths ranged from 75–242 MPa for Si3N4-to-Incoloy 909 joints and from 30–127 MPa for the Si3N4-to-Inconel 718 joints. At 500 °C the joint strength was 120 MPa while at 650°C and 950°C the joints strengths were less than 20 MPa. These low strengths at 650°C and 950°C were attributed to a reduction in the shrink-fit and to low braze strength at these high temperatures. Finite element analysis (FEA) and a probabilistic failure theory (CARES) were used to predict the joint strengths. The predicted joint strengths agreed well with measured joint strengths in torsional loading at 20°C. Torsion tests were also performed at 650°C. Aspects of the material systems, residual stresses, mechanical behavior, and strength predictions are presented. Two new braze alloys based on the Au-Ni-Cr-Fe system were used to overcome the poor high temperature strength. Joints made with these brazes had good strength (85 MPa and 35 N-m) at 650°C.

Synthesis and Luminescence Properties of Tris (8-Hydroxyquinoline) Iron Spindle-Like Structures at Room Temperature

2011 ◽  
Vol 391-392 ◽  
pp. 225-229 ◽  
Author(s):  
Qing Hong Kong ◽  
Hong Liu ◽  
Yun Long Zhang ◽  
Yong Sheng Yan
Keyword(s):  
Electron Microscopy ◽  
Room Temperature ◽  
Blue Shift ◽  
Solvent System ◽  
Iron Complex ◽  
Molecular Formula ◽  
Gravimetric Analysis ◽  
Element Analysis ◽  
Transmission Electron ◽  
Fourier Transformation Infrared Spectroscopy

Spindle-like bis (8-hydroxyquinoline) iron (FeQ3) complex has been synthesized with a facile method in a mixed solvent system at room temperature for 12 h. The molecular formula of the products is speculated by the C, H and N element analysis and thermal gravimetric analysis, and Fourier-transformation infrared spectroscopy was also utilized to measure its structure, which further confirm the molecular formula of the products. The observation of field emission scanning electron microscopy and transmission electron microscopy shows that the morphology of tris (8-hydroxyquinoline) iron complex is spindle-like structure. The photoluminescence of the products were also investigated. The results indicate that the photoluminescence emission of FeQ3spindles shows obvious blue shift contrasted with that of 8-hydroxyquinoline.

The Fire Resistance Performance of Double-Layer Square Pyramid Silo-Shell Structure under Fire

2013 ◽  
Vol 405-408 ◽  
pp. 2305-2310
Author(s):  
Ling Feng Gong ◽  
Yin Bai ◽  
Jian Lei Zhai
Keyword(s):  
Double Layer ◽  
Fire Resistance ◽  
Shell Structure ◽  
Room Temperature ◽  
Uniform Temperature ◽  
Global Instability ◽  
Element Analysis ◽  
Fire Temperature ◽  
Resistance Performance ◽  
Typical Temperature

With fire temperature rising, elastic modulus of steel would be reduce, which then would lead to global instability phenomenon of double-layer square pyramid silo-shell structure. In order to analyze its fire resistance performance under high fire temperature, different geometric parameters were set based on the effect factors when it operated normally at room temperature. To analyze its displacement change by conducting nonlinear finite element analysis which was under the two typical temperature rising cases including global non-uniform temperature and localized high temperature. Then, with the temperature rising, the fire resistance performance and the maxium displacement changing rule were obtained.

Study of the Effect of Tool Wear on Cutting Ti6Al4V Process

2013 ◽  
Vol 690-693 ◽  
pp. 2030-2035
Author(s):  
Shu Bao Yang ◽  
Hong Chao Ni ◽  
Guo Hui Zhu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Key Factors ◽  
Serrated Chip ◽  
Comprehensive Properties ◽  
Commercial Applications ◽  
On Chip ◽  
Rapid Tool

Ti6Al4V alloy is widely used in the aircraft industry, marine and the commercial applications due to its excellent comprehensive properties. However, its poor machinability prevents it from application widely, and the rapid tool wear is one of the key factors. The FEM models of cutting titanium alloy are established. The effect of tool wear on chip morphology, cutting temperature and cutting force are studied. The simulation results show that: the cutting force and cutting temperature will rise with the increase of tool wear. Furthermore, the degree of chip deformation will improve, but the frequency of serrated chip tooth occurred will decrease.

REVIEW ON IMPROVING WEAR AND CORROSION RESISTANCE OF STEELS VIA PLASMA ELECTROLYTIC SATURATION TECHNOLOGY

2016 ◽  
Vol 23 (04) ◽  
pp. 1630002 ◽  
Author(s):  
NAIMING LIN ◽  
RUIZHEN XIE ◽  
PENG ZHOU ◽  
JIAOJUAN ZOU ◽  
YONG MA ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
High Hardness ◽  
High Voltage Power Supply ◽  
Quenching Effect ◽  
Wear And Corrosion ◽  
The Status ◽  
Surface Performance ◽  
Steel Surfaces ◽  
Wear And Corrosion Resistance ◽  
Plasma Electrolytic

Plasma electrolytic saturation (PES) technique which holds the advantages of short treating time and limited heating influence and immediate quenching effect is conducted under high voltage power supply in some electrolyte has been extensively applied to enhance the surface performance of metallic materials. Steel is widely used in various fields thanks to its promising merits of easy workability, plasticity, toughness and weldability. It accounts for a large proportion in the application scope of the metal materials. Steel surfaces with good corrosion resistance, promising wear resistance and high hardness would be obtained by PES. Meanwhile, uniformed coatings can be formed without special requirements for substrate geometries using the PES. This paper first presents a brief introduction of the technological principle of PES. The status on studies and applications of PES for improving surface performance of steels has been reviewed.

Indentation Creep of Molybdenum: Comparison Between Thin Film and Bulk Material

1994 ◽  
Vol 356 ◽  
Author(s):  
K. B. Yoder ◽  
D. S. Stone ◽  
J. C. Lin ◽  
R. A. Hoffmann
Keyword(s):  
Thin Film ◽  
Grain Size ◽  
Room Temperature ◽  
Bulk Material ◽  
High Hardness ◽  
Rate Sensitivity ◽  
Indentation Creep ◽  
Creep Properties ◽  
Measurement Path ◽  
Arc Evaporation

AbstractIndentation creep, load relaxation, and rate-change experiments probe room temperature and 80°C creep properties of a 1.3 μm-thick molybdenum film on silicon. The film, with 0.51 GPa compressive stress, 8 GPa hardness and estimated 40 nm grain size, was deposited using steered-arc evaporation at -17V bias. Despite its small grain size and high hardness, the thin film behaves like bulk molybdenum does: the rate sensitivity of the hardness is only weakly-dependent on measurement path (as with bulk material), and activation volumes calculated based on strain rate sensitivity are consistent with those of bulk molybdenum We suspect deformation mechanisms are similar to those in bulk molybdenum under similar conditions.

Corrosion and Wear Protection through Micro Arc Oxidation Coatings in Aluminum and Its Alloys

2019 ◽  
Author(s):  
L. Rama Krishna ◽  
G. Sundararajan
Keyword(s):  
Corrosion Resistance ◽  
Surface Properties ◽  
High Hardness ◽  
Basic Mechanism ◽  
Industrial Applications ◽  
Corrosion Properties ◽  
Micro Arc Oxidation ◽  
Coating Formation ◽  
Wear And Corrosion Resistance ◽  
Technological Limitations

This article presents the brief overview of fairly recent and eco-friendly micro arc oxidation (MAO) coating technology. The weight-cost-performance benefits in general raised the interest to utilize lightweight materials, especially the aluminum and its alloys. Despite numerous engineering advantages, the aluminum alloys themselves do not possess suitable tribology and corrosion resistance. Therefore, improvements in surface properties are essential to enable developing potential industrial applications. For improving wear and corrosion resistance of Al alloys, the most demanding surface properties are high hardness and chemical inertness. The technical and technological limitations associated with traditional anodizing and hard anodizing processes have been the strongest driving force behind the development of new MAO technology. While presenting the key technological elements associated with the MAO process, the basic mechanism of coating formation and its phase gradient nature is presented. Influence of various process parameters including the electrolyte composition has been discussed. The typical microstructural features and distribution of α- and γ-Al2O3 phases across the coating thickness as a key strategy to form dense coatings with required mechanical, tribological, and corrosion properties which are vital to meet potential application demands are briefly illustrated.

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