Cutting Tool Crater Wear Measurement in Turning Using Chip Geometry and Genetic Programming

2015 ◽  
Vol 6 (1) ◽  
pp. 47-60 ◽  
Author(s):  
Mohammad Zadshakoyan ◽  
Vahid Pourmostaghimi
Keyword(s):  
Tool Wear ◽  
Cutting Speed ◽  
Machining Process ◽  
Turning Process ◽  
Effective Parameters ◽  
Crater Wear ◽  
Geometrical Features ◽  
Tool Wear Estimation ◽  
Industry Automation ◽  
And Control

Tool wear prediction plays an important role in industry automation for higher productivity and acceptable product quality. Therefore, in order to increase the productivity of turning process, various researches have been made recently for tool wear estimation and classification in turning process. Chip form is one of the most important factors commonly considered in evaluating the performance of machining process. On account of the effect of the progressive tool wear on the shape and geometrical features of produced chip, it is possible to predict some measurable machining outputs such as crater wear. According to experimentally performed researches, cutting speed and cutting time are two extremely effective parameters which contribute to the development of the crater wear on the tool rake face. As a result, these parameters will change the chip radius and geometry. This paper presents the development of the genetic equation for the tool wear using occurred changes in chip radius in turning process. The development of the equation combines different methods and technologies like evolutionary methods, manufacturing technology, measuring and control technology with the adequate hardware and software support. The results obtained from genetic equation and experiments showed that obtained genetic equations are correlated well with the experimental data. Furthermore, it can be used for tool wear estimation during cutting process and because of its parametric form, genetic equation enables us to analyze the effect of input parameters on the crater wear parameters.

Metaheuristics in Manufacturing

2018 ◽  
pp. 118-142 ◽  
Author(s):  
Mohammad Zadshakoyan ◽  
Vahid Pourmostaghimi
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Process ◽  
Machining Process ◽  
Turning Process ◽  
Effective Parameters ◽  
Crater Wear ◽  
Tool Wear Estimation ◽  
Industry Automation

The state of a cutting tool is an important factor in any metal cutting process as additional costs in terms of scrapped components, machine tool breakage and unscheduled downtime result from worn tool usage. Therefore, tool wear prediction plays an important role in industry automation for higher productivity and acceptable product quality. Therefore, in order to increase the productivity of turning process, various researches have been made recently for tool wear estimation and classification in turning process. Chip form is one of the most important factors commonly considered in evaluating the performance of machining process. On account of the effect of the progressive tool wear on the shape and geometrical features of produced chip, it is possible to predict some measurable machining outputs such as crater wear. According to experimentally performed researches, cutting speed and cutting time are two extremely effective parameters which contribute to the development of the crater wear on the tool rake face. As a result, these parameters will change the chip radius and geometry. This chapter presents the development of the genetic equation for the tool wear using occurred changes in chip radius in turning process. The development of the equation combines different methods and technologies like evolutionary methods, manufacturing technology, measuring and control technology with the adequate hardware and software support. The results obtained from genetic equation and experiments showed that obtained genetic equations are correlated well with the experimental data. Furthermore, it can be used for tool wear estimation during cutting process and because of its parametric form, genetic equation enables us to analyze the effect of input parameters on the crater wear parameters.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

2021 ◽  
Vol 18 (4) ◽  
pp. 9188-9207
Author(s):  
Mahendran Samykano ◽  
J. Kananathan ◽  
K. Kadirgama ◽  
A. K. Amirruddin ◽  
D. Ramasamy ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Machining Process ◽  
Alumina Nanoparticles ◽  
Working Fluid ◽  
Depth Of Cut ◽  
Nanoparticle Concentration

The present research attempts to develop a hybrid coolant by mixing alumina nanoparticles with cellulose nanocrystal (CNC) into ethylene glycol-water (60:40) and investigate the viability of formulated hybrid nanocoolant (CNC-Al2O3-EG-Water) towards enhancing the machining behavior. The two-step method has been adapted to develop the hybrid nanocoolant at various volume concentrations (0.1, 0.5, and 0.9%). Results indicated a significant enhancement in thermal properties and tribological behaviour of the developed hybrid coolant. The thermal conductivity improved by 20-25% compared to the metal working fluid (MWF) with thermal conductivity of 0.55 W/m℃. Besides, a reduction in wear and friction coefficient was observed with the escalation in the nanoparticle concentration. The machining performance of the developed hybrid coolant was evaluated using Minimum Quantity Lubrication (MQL) in the turning of mild steel. A regression model was developed to assess the deviations in the tool flank wear and surface roughness in terms of feed, cutting speed, depth of the cut, and nanoparticle concentration using Response Surface Methodology (RSM). The mathematical modeling shows that cutting speed has the most significant impact on surface roughness and tool wear, followed by feed rate. The depth of cut does not affect surface roughness or tool wear. Surface roughness achieved 24% reduction, 39% enhancement in tool length of cut, and 33.33% improvement in tool life span. From this, the surface roughness was primarily affected by spindle cutting speed, feed rate, and then cutting depth while utilising either conventional water or composite nanofluid as a coolant. The developed hybrid coolant manifestly improved the machining behaviour.

scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

The Cutting Speed Influences on Tool Wear of ZTA Ceramic Cutting Tools and Surface Roughness of Work Material Stainless Steel 316L during High Speed Machining

2016 ◽  
Vol 840 ◽  
pp. 315-320 ◽  
Author(s):  
Afifah Mohd Ali ◽  
Norazharuddin Shah Abdullah ◽  
Manimaran Ratnam ◽  
Zainal Arifin Ahmad
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
High Speed ◽  
Dense Body ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Stainless Steel 316L ◽  
Crater Wear ◽  
Matlab Programming

The purpose of this research is to find the effects of cutting speed on the performance of the ZTA ceramic cutting tool. Three types of ZTA tools used in this study which are ZTA-MgO(micro), ZTA-MgO(nano) and ZTA-MgO-CeO2. Each of them were fabricated by wet mixing the materials, then dried at 100°C before crushed into powder. The powder was pressed into rhombic shape and sintered at 1600°C at 4 hours soaking time to yield dense body. To study the effect of the cutting speed on fabricated tool, machining was performed on the stainless steel 316L at 1500 to 2000 rpm cutting speed. Surface roughness of workpiece was measured and the tool wears were analysed by using optical microscope and Matlab programming where two types of wear measured i.e. nose wear and crater wear. Result shows that by increasing the cutting speed, the nose wear and crater wear increased due to high abrasion. However, surface roughness decreased due to temperature rise causing easier chip formation leaving a good quality surface although the tool wear is increased.

Control Method for Elimination of Self–Excited Oscillations during Turning

2010 ◽  
Vol 164 ◽  
pp. 171-176 ◽  
Author(s):  
Tomáš Březina ◽  
Jan Vetiška ◽  
Petr Blecha ◽  
Pavel Houška
Keyword(s):  
Tool Wear ◽  
Computer Model ◽  
Pid Controller ◽  
Control Method ◽  
The Self ◽  
Machining Process ◽  
Geometric Accuracy ◽  
Turning Process ◽  
Machined Surface ◽  
Excited Oscillation

The oscillations occurring between the tool and the machined area during the turning process lead to degradation of the machined surface, cause poor geometric accuracy, accelerate tool wear and generate noise. This paper deals with the possibility of elimination of these self-excited oscillations by changing the parameters of the turning process. On the basis of the regenerative principle of self-excited oscillation generation, a computer model of the machining process was developed. Furthermore, a PID controller was proposed to control the compensation of the vibrations and its suitability for elimination of the self-excited oscillations was verified experimentally.

Study on Cutting Performance of the Alumina Based Nanocomposite Ceramic Tool

2014 ◽  
Vol 941-944 ◽  
pp. 1917-1921
Author(s):  
Qi Fen Zhou ◽  
Peng Zhou ◽  
Hai Ying Zhang
Keyword(s):  
Tool Wear ◽  
Failure Modes ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Crater Wear ◽  
Tool Failure ◽  
Ceramic Tools ◽  
Ceramic Cutting Tool ◽  
Adhesion Wear

In this paper, the oxide nanometer composite cutting performance of ceramic tools cutting cast iron were studied. And the tool failure modes were mainly analyzed. Through the study found that, with the increase of tool wear with cutting speed, failure forms mainly adhesion wear. When the cutting speed is low, the knife before the crater wear become the main form of ceramic cutting tool wear, boundary wear and the surface of the knife after wear is also very serious. And in the process of cutting, the collapse edge can also occur now; With the increase of cutting speed, collapse become the main failure forms of cutter blade.

Identification, Analysis and Evolution of the Mechanisms of Wear for Secondary Adhesion for Dry Turning Processes of Al-Cu Alloys

2010 ◽  
Vol 107 ◽  
pp. 141-146 ◽  
Author(s):  
Moisés Batista ◽  
J. Salguero ◽  
Alvaro Gómez ◽  
M.S. Carrilero ◽  
Miguel Álvarez ◽  
...  
Keyword(s):  
Tool Wear ◽  
Critical Size ◽  
Main Tool ◽  
Machining Process ◽  
Rake Face ◽  
Turning Process ◽  
Dry Turning ◽  
Cu Alloys ◽  
Tool Wear Mechanism ◽  
Identification Analysis

In this work, Stereoscopic Optical Microscopy (SOM), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) have been applied for analyzing the evolution of tool wear during the dry turning process of aerospace Al-Cu alloys. The results derived from this analysis have revealed that secondary adhesion is the main tool wear mechanism that takes place in such process. So, in the first instants of the machining process, a Built-Up Layer (BUL) is developed onto the tool rake face by thermomechanical causes, promoting the conditions for developing a Built-Up Edge (BUE) which grows to a critical size. Starting from it, BUE is extruded giving rise to secondary BUL-BUE effects. When these are removed, tool particles are dragged out provoking the tool wear.

scholarly journals Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6106
Author(s):  
Waleed Ahmed ◽  
Hussien Hegab ◽  
Atef Mohany ◽  
Hossam Kishawy
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inclination Angle ◽  
Feed Rate ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Hardened Steel ◽  
Machining Process ◽  
Aisi 4140 ◽  
Steel Aisi

It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle were the selected design variables, while the tool wear, surface roughness, and material removal rate (MRR) were the studied outputs. The optimal surface roughness was obtained at a cutting speed of 240 m/min, an inclination angle of 20°, and a feed rate of 0.1 mm/rev. In addition, the minimum flank tool wear was observed at a cutting speed of 70 m/min, an inclination angle of 10°, and a feed rate of 0.15 mm/rev. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer’s interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140 within the selected ranges.

scholarly journals Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5697
Author(s):  
Tarek Elgnemi ◽  
Victor Songmene ◽  
Jules Kouam ◽  
Martin B.G. Jun ◽  
Agnes Marie Samuel
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Dust Emission ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Specific Cutting Energy ◽  
Fine Dust ◽  
Cutting Energy ◽  
Cutting Speeds

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

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