Tool Wear Mechanisms in High Speed Machining Ductile Cast Iron

2010 ◽  
Vol 29-32 ◽  
pp. 1527-1531
Author(s):  
Fa Zhan Yang ◽  
Jian Qiang Zhou ◽  
Guang Yao Meng ◽  
Jun Zhao ◽  
Chang He Li
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Wear Behavior ◽  
Orthogonal Cutting ◽  
Ductile Cast Iron ◽  
Cemented Carbide ◽  
Rake Face ◽  
High Speed Cutting

Wear behavior of WC based nanocomposite cutting tool when high speed cutting ductile cast iron was investigated. Orthogonal cutting tests were carried out on a CA6140 lathe using three speeds, namely, 100, 215 and 287m min-1. The WC based nanocomposite tool is found to be superior to cemented carbide tools (YG8). The tool life is prolonged 60% as compared to cemented carbide, as the width of the wear land (VB), which was monitored at selected time intervals. Meanwhile, the topography of worn surfaces was scanned by a profilemeter. Wear characterization of the rake face and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM). Results showed that distinctive traces of single abrasive tool wear event were found on the rake face of the tool, additionally, the adhesion wear is the main wear mechanism in the flank face of the tool. However, the extent of improvement in tool life depends strongly on the cutting conditions, with the greatest benefits being seen at higher cutting speeds and feed rates.

Wear Performance Evaluation of Tungsten Carbide Taps in Blind Hole Tapping Cast Iron

2010 ◽  
Vol 126-128 ◽  
pp. 755-759 ◽  
Author(s):  
Ming Chen ◽  
Xiao Hui Zhang ◽  
Bing Han ◽  
Bin Rong ◽  
Gang Liu
Keyword(s):  
Cast Iron ◽  
Tungsten Carbide ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Ductile Cast Iron ◽  
Cutting Performance ◽  
Production Lines ◽  
High Speed Cutting ◽  
Ticn Coating

The engineblock and cylinderhead of automobile are usually made of cast iron, and tapping of blind holes is one of the most demanding operations. As usual, tapping is the final process for an engineblock, and the failure of taps can disable the engineblock possibly. The productivity is restricted because of the low cutting speed and poor wear resistance of high speed steel (HSS) taps. Thereby, according to the demand on high speed cutting and low tact time of modern engine production lines, several new typical special tungsten carbide taps are developed and their cutting performance are evaluated in comparison with the commercial taps. In the process of tapping blind holes in gray cast iron and ductile cast iron, several aspects are studied comparatively such as wear mechanism of the first complete and the last incomplete tooth, tap structure, wear of TiCN coating and effects of coolant on cutting performance of taps. This study indicates that straight coated taps with fewer flutes are suitable for high speed tapping of cast iron.

Tool Life in High Speed Turning with Negative Rake Angle

2011 ◽  
Vol 264-265 ◽  
pp. 1009-1014 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz H.F. Al Hazza
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
High Speed Cutting ◽  
Life Estimation ◽  
High Speed Turning

The present work studies some aspects of turning process applied on mild steel using cermets tools at high speed cutting (1000mm/min) by using negative rake angle (0 to-12). The influence of increasing the cutting speed and negative rake angle on flank tool wear, cutting forces, feeding forces and tool temperature were analyzed. The research studies and concentrates on the tool life estimation and the effect of the negative rake angle and higher cutting speed on tool life. It was found that the maximum tool life is obtained in (-6) rake angle for the cutting parameters.

scholarly journals Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4293
Author(s):  
Mahshad Javidikia ◽  
Morteza Sadeghifar ◽  
Victor Songmene ◽  
Mohammad Jahazi
Keyword(s):  
Residual Stress ◽  
Tool Wear ◽  
Residual Stresses ◽  
Feed Rate ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Research Work ◽  
Fe Model ◽  
High Speed Cutting ◽  
Machining Forces

The present research work aimed to study the effects of cutting environments and conditions on tool wear and residual stresses induced by orthogonal cutting of AA6061-T6. Cutting environments included dry- and flood-coolant modes and cutting conditions consisted of cutting speed and feed rate. A 2D finite element (FE) model was developed to predict tool wear and residual stresses and was validated by experimental measurements including machining forces, tool wear, and residual stresses. This was obtained by exploring various magnitudes of the shear friction factor and heat transfer coefficient and choosing proper coefficients using the calibration of the predicted results with the measured ones. The experimental results showed that the effect of cutting environment including dry and flood-coolant modes was negligible on machining forces. The experimental investigation also demonstrated that increasing feed rate raised machining forces, tool wear and residual stresses in both cutting environments. Low Speed Cutting (LSC) led to the highest value of tool wear and High Speed Cutting (HSC) provided the lowest values of resultant machining forces and residual stresses in both modes. Flood-coolant mode reduced tool wear and slightly decreased tensile residual stresses in comparison with dry mode. As a result, low feed rate and high-speed cutting under flood-coolant mode were proposed in order to improve tool wear and residual stress in orthogonal cutting of AA6061-T6.

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

Highlights of the DARPA Advanced Machining Research Program

1985 ◽  
Vol 107 (4) ◽  
pp. 325-335 ◽  
Author(s):  
R. Komanduri ◽  
D. G. Flom ◽  
M. Lee
Keyword(s):  
Thermal Properties ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Research Program ◽  
High Speed ◽  
Metal Removal ◽  
High Speed Machining ◽  
Advanced Machining ◽  
Nickel Base

Results of a four-year Advanced Machining Research Program (AMRP) to provide a science base for faster metal removal through high-speed machining (HSM), high-throughput machining (HTM) and laser-assisted machining (LAM) are presented. Emphasis was placed on turning and milling of aluminum-, nickel-base-, titanium-, and ferrous alloys. Experimental cutting speeds ranged from 0.0013 smm (0.004 sfpm) to 24,500 smm (80,000 sfpm). Chip formation in HSM is found to be associated with the formation of either a continuous, ribbon-like chip or a segmental (or shear-localized) chip. The former is favored by good thermal properties, low hardness, and fcc/bcc crystal structures, e.g., aluminum alloys and soft carbon steels, while the latter is favored by poor thermal properties, hcp structure, and high hardness, e.g., titanium alloys, nickel base superalloys, and hardened alloy steels. Mathematical models were developed to describe the primary features of chip formation in HSM. At ultra-high speed machining (UHSM) speeds, chip type does not change with speed nor does tool wear. However, at even moderately high speeds, tool wear is still the limiting factor when machining titanium alloys, superalloys, and special steels. Tool life and productivity can be increased significantly for special applications using two novel cutting tool concepts – ledge and rotary. With ledge inserts, titanium alloys can be machined (turning and face milling) five times faster than conventional, with long tool life (~ 30 min) and cost savings up to 78 percent. A stiffened rotary tool has yielded a tool life improvement of twenty times in turning Inconel 718 and about six times when machining titanium 6A1-4V. Significantly increased metal removal rates (up to 50 in.3/min on Inconel 718 and Ti 6A1-4V) have been achieved on a rigid, high-power precision lathe. Continuous wave CO2 LAM, though conceptually feasible, limits the opportunities to manufacture DOD components due to poor adsorption (~ 10 percent) together with high capital equipment and operating costs. Pulse LAM shows greater promise, especially if new laser source concepts such as face pump lasers are considered. Economic modeling has enabled assessment of HSM and LAM developments. Aluminum HSM has been demonstrated in a production environment and substantial payoffs are indicated in airframe applications.

scholarly journals Microstructure, Mechanical Properties and Wear Behavior of High-Velocity Oxygen-Fuel (HVOF) Sprayed (Cr3C2-NiCr+Al) Composite Coating on Ductile Cast Iron

Coatings ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 840 ◽  
Author(s):  
Marzanna Ksiazek ◽  
Lukasz Boron ◽  
Adam Tchorz
Keyword(s):  
Cast Iron ◽  
Electron Microscope ◽  
High Velocity ◽  
Bending Strength ◽  
Wear Behavior ◽  
Ductile Cast Iron ◽  
Wear Behaviour ◽  
Wear Properties ◽  
Alloy Matrix ◽  
X Ray

In the present work Cr3C2-NiCr powder containing Al particles was deposited on ductile cast iron with high-velocity oxy-fuel (HVOF) thermal spray coating technique. An investigation was conducted to determine the role of Al particles in the Cr3C2-NiCr coating produced with HVOF technique on microstructure, mechanical and wear properties in a system Cr2C3-NiCr coating/ductile cast iron. The microstructure of the HVOF-sprayed Cr3C2-NiCr+Al coating was characterized by light microscopy, X-ray diffraction (XRD), scanning electron microscope (SEM), transmission electron microscope (TEM) and energy dispersive X-ray spectroscopy (EDS). Microstructure analysis reveals the formation of coating with low porosity, good adhesion to the substrate and dense structure with irregularly shaped particles of Al arranged in strips and finely fragmented Cr3C2 particles embedded in a nanocrystalline Ni-Cr alloy matrix. In addition, the results were discussed in reference to examination of bending strength considering cracking and delamination in the system of (Cr3C2-NiCr+Al)/ductile cast iron as well as microhardness and wear resistance of the coating. It was found that the addition of Al particles significantly increased resistance to cracking and wear behaviour in the studied system.

Investigation of the lubricated wear behavior of ductile cast iron and quenched and tempered alloy steel for possible use in worm gearing

Wear ◽  
2016 ◽  
Vol 350-351 ◽  
pp. 68-73 ◽  
Author(s):  
Vigilio Fontanari ◽  
Matteo Benedetti ◽  
Christian Girardi ◽  
Lorenzo Giordanino
Keyword(s):  
Cast Iron ◽  
Alloy Steel ◽  
Wear Behavior ◽  
Ductile Cast Iron ◽  
Worm Gearing

Investigation of Surface Characteristics and Chip Morphology in High Speed Cutting of Inconel718 Based on SHPB System

2019 ◽  
Author(s):  
Zengqiang Wang ◽  
Zhanfei Zhang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting

Abstract High speed cutting (HSC) technology has the characteristics of high material removal rates and high machining precision. In order to study the relationships between chip morphology and machining surface characteristic in high speed cutting of superalloy Inconel718. High-speed orthogonal cutting experiment are carried out by used a high speed cutting device based on split Hopkinson pressure bar (SHPB). The specimen surfaces and collected chips were then detected with optical microscope, scanning electron microscope and three-dimensional surface profile measuring instrument. The results show that within the experimental parameters (cutting speed from 8–16m/s, depth of cut 0.1–0.5mm), the obtained chips are sawtooth chips and periodic micro-ripple appear on the machined surface. With the cutting speed increases, machining surface roughness is decreases from 1.4 to 0.99μm, and the amplitude of periodic ripples also decreases. With the cutting depth increases, the machining surface roughness increases from 0.96 to 5.12μm and surface topography becomes worse. With the increase of cutting speed and depth of cut, the chips are transform from continues sawtooth to sawtooth fragment. By comparing the frequency of surface ripples and sawtooth chips, it is found that they are highly consistent.

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