Tool Wear of Diamond-Like Carbon-Coated High-Speed Steel with a Cr-Based Interlayer in Cutting of Aluminum Alloys

2012 ◽  
Vol 152-154 ◽  
pp. 74-79
Author(s):  
Tadahiro Wada ◽  
Koji Iwamoto ◽  
Hiroaki Sugita
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Diamond Like Carbon ◽  
Aluminum Alloy 6061 ◽  
Coated Tool ◽  
Alloy 6061

In cutting aluminum alloy 6061, continuous chips have a negative influence on the machining operation. Usually, Pb is added in order to break continuous chips. However, from the standpoint of environmental protection, it is necessary to improve chip breakability without adding Pb. One effective measure to improve chip breakability is by adding Si to aluminum alloy 6061. However, the influence of Si content on tool wear has not been fully examined. In this study, in order to clarify the influence of a diamond-like carbon (DLC) coating layer with a Cr-based interlayer, namely (Al,Cr)N, on cutting performance, aluminum alloys having different Si contents were turned. The substrate of the tool material was high-speed steel (1.4%C). The tool wear and the surface roughness were experimentally investigated. The following results were obtained: (1) In cutting two kinds of Al-Si alloys, namely the Al-2%Si alloy and Al-4%Si alloy, the progress of wear of the DLC/(Al,Cr)N-coated tool was slower than that of the DLC-coated tool. Therefore, the (Al,Cr)N interlayer was effective for decreasing the tool wear of the DLC-coated tool. (2) The wear progress of the two kinds of DLC-coated tools in cutting of Al-4%Si alloy was faster than that in cutting of Al-2%Si alloy. (3) In cutting of Al-2%Si alloy with the (Al,Cr)N/DLC-coated tool, the surface roughness was almost constant in the range of a cutting distance from 0.1 km to 9.5 km.

Cutting Performance of Diamond-Like Carbon Coated Tool in Cutting of Aluminum Alloys

2010 ◽  
Vol 638-642 ◽  
pp. 368-373 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Aluminum Alloy ◽  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Force ◽  
Coating Layer ◽  
Cutting Performance ◽  
Diamond Like Carbon ◽  
Dlc Coating ◽  
Coated Tool ◽  
Alloy 6061

In cutting aluminum alloy 6061, continuous chips have a negative influence on the machining operation. Usually, Pb is added in order to break continuous chips. However, from the standpoint of environmental protection, it is necessary to improve chip breakability without adding Pb. One effective measure is improving chip breakability by adding Si in aluminum alloy 6061. However, the influence of Si content on tool wear has not been fully examined. In this study, in order to clarify the influence of a diamond-like carbon (DLC) coating layer on cutting performance, aluminum alloys having different Si contents were turned. The substrate of the tool material was high speed steel (1.4%C). The chip configuration, cutting force and tool wear were experimentally investigated. The following results were obtained: (1) The DLC coating layer was effective for decreasing the cutting force. (2) In cutting Al-2mass%Si alloy, the wear progress of the DLC-coated tool was slower than that of the un-coated tool. The length of a chip with the DLC-coated tool was shorter than that with the un-coated tool.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

scholarly journals Effect of extrusion temperature on the surface roughness of solid state recycled aluminum alloy 6061 chips during turning operation

2017 ◽  
Vol 9 (10) ◽  
pp. 168781401773415 ◽  
Author(s):  
Adham Ezzat Ragab ◽  
Mohamed Adel Taha ◽  
Adel Taha Abbas ◽  
Essam Ali Al Bahkali ◽  
Ehab Adel El-Danaf ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Solid State ◽  
Extrusion Temperature ◽  
Turning Operation ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

A Study on the Parameters in Hard Turning of High Speed Steel

2018 ◽  
Vol 5 (2) ◽  
pp. 1-12
Author(s):  
Krishnaraj Vijayan ◽  
N. Gouthaman ◽  
Tamilselvan Rathinam
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Hard Turning ◽  
White Layer ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Contributing Factors

The objectives of hard turning of high speed steel (HSS-M2 Grade) are to investigate the effect of cutting parameters on cutting force, tool wear and surface integrity. This article presents the experimental results of heat treated high speed steel machined in a CNC lathe using cubic boron nitride (CBN) tools. Turing experiments were carried out using central composite design (CCD) method. From the experiments the influence of cutting parameters and their interactions on cutting forces, temperature and surface roughness (Ra) were analyzed. Following this, multi response optimization was done to find the best combination of parameters for minimum force, minimum temperature and minimum surface roughness. The experimental results showed that the most contributing factors were feed followed by depth of cut and spindle speed. A white layer formed during hard turning was also analyzed by scanning electron microscope (SEM) and the results showed that it was greatly influenced by the speed and depth of cut. Tool wear was experiments were conducted at the optimum cutting conditions and it was noted that the tool satisfactorily performed up to 10 minutes at dry condition.

scholarly journals Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1628
Author(s):  
Mohd Fathullah Ghazali ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Paweł Pietrusiewicz ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Potential Use

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

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