Technical Resource of the Cutting Wedge is the Foundation of the Machining Regime Determination

2020 ◽  
Vol 10 (2) ◽  
pp. 1-17 ◽  
Author(s):  
Viktor P. Astakhov ◽  
Stanislav V. Shvets
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Tool Wear ◽  
Work Done ◽  
Cutting System ◽  
Small Tool

This article argues that cutting tool wear is not just a particular case of wear found in general machinery because the whole amount of energy required for cutting is transmitted through relatively small tool-chip and tool-workpiece interfaces causing extremely high contact temperatures and pressures. This article discusses a considerably different approach to the determination of the cutting speed based upon the energy passing through the cutting wedge. Moreover, it discusses that, for a given tool material/geometry, there is a limited amount of such energy that the cutting wedge can sustain before reaching the criterion of tool life. This limit is considered as the technical resource of the cutting tool. The article establishes and verifies the existence of the detect correlation between the works done in the cutting system and in tool wear. Based on this finding, the equations to calculate the cutting speed for a chosen tool life and/or the tool life for a chosen cutting speed are proposed. The concept of the technical resource of the cutting wedge is introduced as the total amount of work done before it fails.

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.

Influence of Edge Preparation on Cutting Tool Wear

2012 ◽  
Vol 201-202 ◽  
pp. 1178-1181
Author(s):  
Guo Bing Chai ◽  
Wei Wang ◽  
Ai Bing Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Impact Resistance ◽  
Cutting Tools ◽  
Medium Carbon Steel ◽  
Cutting Edge ◽  
Cutting Tool Wear ◽  
Edge Radius ◽  
Edge Preparation

Edge preparation is not only the process of grinding proper geometry of cutting edge or removing micro-cracks on cutting edge region, but also a way of improving cutting tool life. In this study, cutting models with different cutting edge radius were set up with FEM software. Medium carbon steel cutting tests were carried out using cutting tools with different edge radius. Cutting tool wear was simulated and measured for comparison. The simulation results show that edge radius has influences on tool wear. Tool cutting behavior is concerned with edge radius. A proper edge radius will improve the tool life. The experimental results show that proper edge preparation could improve tool impact resistance capability and reduce tool wear. The cutting tool life can be prolonged with suitable edge preparation. Edge preparation can improve cutting performance of cutting tool.

scholarly journals System for Tool-Wear Condition Monitoring in CNC Machines under Variations of Cutting Parameter Based on Fusion Stray Flux-Current Processing

Sensors ◽  
2021 ◽  
Vol 21 (24) ◽  
pp. 8431
Author(s):  
Arturo Yosimar Jaen-Cuellar ◽  
Roque Alfredo Osornio-Ríos ◽  
Miguel Trejo-Hernández ◽  
Israel Zamudio-Ramírez ◽  
Geovanni Díaz-Saldaña ◽  
...  
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Economic Benefits ◽  
Numerical Control ◽  
Cnc Machines ◽  
Cutting Tool Wear

The computer numerical control (CNC) machine has recently taken a fundamental role in the manufacturing industry, which is essential for the economic development of many countries. Current high quality production standards, along with the requirement for maximum economic benefits, demand the use of tool condition monitoring (TCM) systems able to monitor and diagnose cutting tool wear. Current TCM methodologies mainly rely on vibration signals, cutting force signals, and acoustic emission (AE) signals, which have the common drawback of requiring the installation of sensors near the working area, a factor that limits their application in practical terms. Moreover, as machining processes require the optimal tuning of cutting parameters, novel methodologies must be able to perform the diagnosis under a variety of cutting parameters. This paper proposes a novel non-invasive method capable of automatically diagnosing cutting tool wear in CNC machines under the variation of cutting speed and feed rate cutting parameters. The proposal relies on the sensor information fusion of spindle-motor stray flux and current signals by means of statistical and non-statistical time-domain parameters, which are then reduced by means of a linear discriminant analysis (LDA); a feed-forward neural network is then used to automatically classify the level of wear on the cutting tool. The proposal is validated with a Fanuc Oi mate Computer Numeric Control (CNC) turning machine for three different cutting tool wear levels and different cutting speed and feed rate values.

scholarly journals Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Harun Gokce
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Taguchi Method ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Tool Wear ◽  
Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

THEORETICAL ANALYSIS OF PRODUCTIVITY IN DIFFERENT VARIANTS OF OPTIMIZATION OF CUTTING SPEED IN TURNING

2020 ◽  
pp. 7-13
Author(s):  
V. F. Bezyazychzny ◽  
A. V. Kordyukov
Keyword(s):  
Tool Wear ◽  
Production Cost ◽  
Cutting Tool ◽  
Operating Cost ◽  
Cutting Speed ◽  
Labor Cost ◽  
Cutting Edge ◽  
Tool Geometry ◽  
Work Piece ◽  
Cutting Tool Wear

Analysis and comparison is presented as to processing performance levels with cutting speeds providing various optimization criteria: minimal cutting tool wear, minimal production cost and maximal cutting performance. It has been established that during machining at the cutting speed corresponding to the minimal cutting tool wear performance is close to the level of productivity when machining at the cutting speed corresponding to the minimal production cost. Results of calculations allow estimating both the performance value and the machinability level of different materials in terms of strength, not only in quality, but also in quantity. This assessment is made subject to the physical and mechanical properties of the work piece and the tool materials, the cutting mode (cutting speed and depth, feed), the tool geometry (cutter tip radius in the plan, cutting edge corner radius, face and clearance angles, major and minor cutting edge angles), as well as the economic performance of cutting (cutting time, cost of machine operation and labor cost, cutting tool operating cost).

Study on Wear Mechanism of Carbide Tool in Machining Inconel 718

2013 ◽  
Vol 589-590 ◽  
pp. 323-326 ◽  
Author(s):  
Yi Hang Fan ◽  
Liang Zhou ◽  
Shuang Zhu Song ◽  
Feng Lian Sun
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Wear Debris ◽  
Oxidation Reaction ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Tool Breakage ◽  
Nickel Based Superalloy ◽  
Cemented Carbide Tools

Tool wear is a problem in machining nickel-based superalloy Inconel 718, and it is thus of great importance to understand and quantitatively predict tool wear. The experiments of machining Inconel 718 with cemented carbide tools (uncoated and coated) were carried out. Some new observations and analysis of tool wear through CCD, SEM and EDS were done. The results showed that at low cutting speed, the built up edge (BUE) formed easily and dropped at last which caused severe cutting tool breakage. When cutting speed came to 30m/min, the main reason that caused cutting tool wear was that the tool material fell off from the tool body at the form of wear debris. What’s more, the element diffusion between tool and workpiece and oxidation reaction all accelerate the formation and the cast of the wear debris.

Study Concerning the Cutting Tool Wear at Drilling of the Stainless Steel X20Cr13

2014 ◽  
Vol 1036 ◽  
pp. 230-234
Author(s):  
Aurelian Vlase ◽  
Marius Iacob ◽  
Ovidiu Blăjină ◽  
Vlad Darie
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Economic Optimization ◽  
Cutting Tool Wear ◽  
Manufacturing Activity ◽  
Process Economic Optimization ◽  
Relationship Of

The researches in the cutting domain have as purpose the cutting process economic optimization. This paper studies the cutting tool wear at drilling of the stainless steel X20Cr13. The experimental data and their subsequent processing represent the original contribution of the authors to the estimation of polytropic exponents and to the assessment in terms of structure of the calculus relation of the cutting tool wear. The obtained relationship of the cutting tool wear on the tool putting surface at drilling of the steel X20Cr13 permits the determination of the wear on the putting surface, in the case of a couple: stainless steel X20Cr13 - Rp5 high-speed spiral drill, depending on the work parameters and the cutting conditions. Putting the condition of wear limitation, from the obtained relation, the cutting speeds are exactly given. The paper also contains graphs for the variation of the tool wear with parameters of the cutting technology. The results can be taken into consideration in the educational studies and in the theoretical technical research. They can be implemented in the manufacturing activity.

Effect of residual elements on the machinability of leaded free machining steels

1980 ◽  
Vol 295 (1413) ◽  
pp. 87-88 ◽  
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Low Carbon ◽  
Wear Rates

The machinability of a material can be defined in terms of the wear rate of the cutting tool used to machine the material. The lower the tool wear rate or the greater the tool life the better the machinability. The wear processes of cutting tools are complicated, but recent work has shown that cutting tool wear rates during machining can be directly related to tool material wear rates when rubbing in a modified crossed cylinder wear experiment (Mills & Akhtar 1975). The wear of cutting tools can be simulated by simple experiments. Here I present results on the effect of total residual levels in leaded low carbon free machining steels on the tool life of M2 high speed steel. The results will be discussed in terms of a simple wear model.

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