PCBN Tool Performance Evaluation Based on Image Analysis of Machining Surface Texture

2007 ◽  
Vol 10-12 ◽  
pp. 762-766 ◽  
Author(s):  
P. Wang ◽  
D.L. Liu ◽  
Yi Zhi Liu ◽  
Xian Li Liu ◽  
Chun Ya Wu
Keyword(s):  
Surface Roughness ◽  
Image Analysis ◽  
Surface Texture ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Polycrystalline Cubic Boron Nitride ◽  
Gray Histogram ◽  
Tool Performance ◽  
Conventional Detection

The Polycrystalline Cubic Boron Nitride (PCBN) cutting tools has have been developed for high speed machining in modern automation manufacture. The machining surface roughness is regarded as an important criterion to assess PCBN cutting tools performance. There are too many problems in conventional detection method. In order to solve that problem, we present a new way that is based on image analysis of machining surface texture to assess surface roughness. The new method is consisted of three steps. It captures surface texture image when machining is finished or pauses. Firstly, RGB histogram is adopted to analyze image pixel information. This means takes advantage of histogram technique and provides more pixel distribution information than gray histogram. Secondly, unsupervised texture segmentation is used based on resonance algorithm. Thirdly, a new estimation parameter E that is the density of surface contour peak is put forward to estimate machining surface roughness.

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

High Precision Cutting and High Speed Interrupted Cutting of Hardened Steel With PCBN Tools

1999 ◽  
Author(s):  
Katsuhito Yoshida ◽  
Satoru Kukino ◽  
Takashi Harada ◽  
Tomohiro Fukaya ◽  
Junichi Shiraishi ◽  
...  
Keyword(s):  
High Precision ◽  
High Speed ◽  
New Technologies ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Precision Machining ◽  
Polycrystalline Cubic Boron Nitride ◽  
Interrupted Cutting ◽  
Pcbn Tools

Abstract PCBN (Polycrystalline Cubic Boron Nitride) cutting tools have become very familiar in the industries for cutting hardened steel parts and the demand for PCBN tools is growing rapidly. One of the reasons for this is the trend of replacing grinding processes with cutting. Although the trend of processing is to use more cutting, there still remains grinding in many processing fields. High precision machining and high speed interrupted machining have been such fields. In this study it has been verified that a novel cutting method can be applied to high precision machining with the smoothness of Rz 0.8 μm and that a new PCBN has sufficient reliability against tool failure in high speed (< 250m/min) interrupted cutting. Thus cutting has become applicable to those machining and the trend of replacement of grinding with cutting will be enhanced. Those new technologies will be introduced in this report.

Evaluation of the Performance of CBN Tools When Turning Austempered Ductile Iron Material

2008 ◽  
Vol 130 (5) ◽  
Author(s):  
K. Aslantas ◽  
İ. Ucun ◽  
K. Gök
Keyword(s):  
Surface Roughness ◽  
Ductile Iron ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Salt Bath ◽  
Austempered Ductile Iron ◽  
Depth Of Cut ◽  
Tool Performance ◽  
Austempering Temperature

The study deals with the machinability properties of austempered ductile iron using cubic boron nitride cutting tools. To emphasize the role of the austempering process, ductile iron specimens were first austenitized in salt bath at 900°C for 60min, after which they were quenched in a salt bath at 250°C and 325°C for 60min. Machining tests were carried out at various cutting speeds under the constant depth of cut and the feed rate. Tool performance was evaluated based on the workpiece surface roughness and flank wear. The influence of the austempering temperature and cutting speed on the chip form was also studied. The results point out that the lower austempering temperature results in the increase in the cutting forces, while better surface roughness is attained.

Characteristic properties of AlTiN and TiN coated HSS materials

2015 ◽  
Vol 67 (2) ◽  
pp. 172-180 ◽  
Author(s):  
Mumin Sahin ◽  
Cenk Misirli ◽  
Dervis Özkan
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Wear Properties ◽  
Content Type ◽  
X Ray ◽  
Number Of Cycles ◽  
Future Work

Purpose – The purpose of this paper is to examine mechanical and metallurgical properties of AlTiN- and TiN-coates high-speed steel (HSS) materials in detail. Design/methodology/approach – In this study, HSS steel parts have been processed through machining and have been coated with AlTiN and TiN on physical vapour deposition workbench at approximately 6,500°C for 4 hours. Tensile strength, fatigue strength, hardness tests for AlTiN- and TiN-coated HSS samples have been performed; moreover, energy dispersive X-ray spectroscopy and X-ray diffraction analysis and microstructure analysis have been made by scanning electron microscopy. The obtained results have been compared with uncoated HSS components. Findings – It was found that tensile strength of TiAlN- and TiN-coated HSS parts is higher than that of uncoated HSS parts. Highest tensile strength has been obtained from TiN-coated HSS parts. Number of cycles for failure of TiAlN- and TiN-coated HSS parts is higher than that for HSS parts. Particularly TiN-coated HSS parts have the most valuable fatigue results. However, surface roughness of fatigue samples may cause notch effect. For this reason, surface roughness of coated HSS parts is compared with that of uncoated ones. While the average surface roughness (Ra) of the uncoated samples was in the range of 0.40 μm, that of the AlTiN- and TiN-coated samples was in the range of 0.60 and 0.80 μm, respectively. Research limitations/implications – It would be interesting to search different coatings for cutting tools. It could be the good idea for future work to concentrate on wear properties of tool materials. Practical implications – The detailed mechanical and metallurgical results can be used to assess the AlTiN and TiN coating applications in HSS materials. Originality/value – This paper provides information on mechanical and metallurgical behaviour of AlTiN- and TiN-coated HSS materials and offers practical help for researchers and scientists working in the coating area.

Mikrofräswerkzeuge mit Schneiden aus cBN*/Micro-cutting tools with cBN cutters

2018 ◽  
Vol 108 (11-12) ◽  
pp. 773-777
Author(s):  
E. Uhlmann ◽  
J. Polte ◽  
M. Polte ◽  
Y. Kuche ◽  
H. Wiesner
Keyword(s):  
Surface Roughness ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
High Strength ◽  
Hardened Steel ◽  
Micro Milling ◽  
Geometric Accuracy ◽  
Micro Cutting ◽  
Core Technology ◽  
Milling Tools

Die Mikrozerspanung ist eine Kerntechnologie bei der Fertigung von Mikrospritzgussformen. Die hohen Ansprüche an die geometrische Genauigkeit und Oberflächenrauheit erfordern den Einsatz hochfester Werkstoffe. Jedoch unterliegen aktuelle Fräswerkzeuge bei der Mikrozerspanung einem hohen Verschleiß. Einen Lösungsansatz bietet der erfolgreich in der Makrozerspanung eingesetzte Schneidstoff kubisch-kristallines Bornitrid (cBN). Ziel der Untersuchungen war es daher, detaillierte Informationen zur Bearbeitung von gehärtetem Stahl mit cBN-Mikrofräswerkzeugen bereitstellen zu können.   Micro-cutting is a core technology for producing micro-injection moulds. High demands on geometric accuracy and surface roughness require high-strength materials. However, current milling tools for micro-cutting suffer from excessiv tool wear. A solution is offered by cutting materials based on cubic Boron Nitride (cBN), which have been used successfully in macro-machining. This article contains detailed information on the machining of hardened steel with micro-milling tools and cutting edges made of cBN.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Machinability of Pearlitic Cast Iron With Cubic Boron Nitride (CBN) Cutting Tools

2002 ◽  
Vol 124 (4) ◽  
pp. 820-832 ◽  
Author(s):  
Jiancheng Liu ◽  
Kazuo Yamazaki ◽  
Hiroyuki Ueda ◽  
Norihiko Narutaki ◽  
Yasuo Yamane
Keyword(s):  
Cast Iron ◽  
Boron Nitride ◽  
Tool Wear ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Conditions ◽  
Machining Center

In order to increase the accurate finishing productivity of pearlitic cast iron, face milling by CBN (Cubic Boron Nitride) cutting tools was studied. The main focus of the study is the machinability investigation of pearlitic cast iron with CBN cutting tools by studying the relationships among machining conditions such as feed rate, cutting speed as well as CBN cutting tool type, tool wear, workpiece surface quality, cutting forces, and cutting temperature. In addition, an emphasis is put on the effect of Al additive in pearlitic cast iron on its machinability and tool wear characteristics. High-speed milling experiments with CBN cutting tools were conducted on a vertical machining center under different machining conditions. The results obtained provide a useful understanding of milling performance by CBN cutting tools.

scholarly journals Kekasaran permukaan pada pemesinan frais mikro Ti 6Al- 4V ELI (extra low intertitial)

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Gusri Akhyar Ibrahim ◽  
Endra Saputra ◽  
Suryadiwansa Harun ◽  
Eko Agus Supriyanto ◽  
Armulani Patihawa
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Titanium Material ◽  
Cutting Zone ◽  
Tool Diameter

One of the ingredients that are popular now is titanium, but titanium is a material that is difficult to process using conventional milling machining because of the poor thermal conductivity of the material so that the high-temperature machining process produced in the cutting zone causes plastic deformation in cutting tools and increased chemical reactivity in titanium. High-speed micro-milling machining can be used for micro machining of hard metals or alloys that are difficult to achieve at low speeds. Micro milling machining in titanium material 6Al-4V ELI with variations in milling tool diameter 1 and 2 mm, spindle speed 10.000 and 15.000 rpm, feed 0,001 and 0,005 mm/rev, depth of cut 100 and 150 μm, which then do data processing using the method taguchi full factorial and theoretical analysis. The results showed that the diameter of the tool and into the depth of cut the most effect on surface roughness, the greater the tool diameter of the milling produced a smaller roughness value, this is inversely proportional to the depth of the cut. The lowest roughness value is 0,26 and the highest roughness value is 0,9. Keywords: Micro milling machining, titanium 6Al-4V ELI, surface roughness.

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