Experimental Investigations on the Effect of Vegetable Based Cutting Fluid in Turning AISI 1040 Steel

2014 ◽  
Vol 541-542 ◽  
pp. 368-373
Author(s):  
Durwesh Jhodkar ◽  
M. Amaranth ◽  
H. Chelladurai ◽  
J. Ramkumar
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Single Point ◽  
Coconut Oil ◽  
Good Alternative ◽  
Cutting Fluid ◽  
Experimental Investigations ◽  
Crater Wear ◽  
Turning Operation ◽  
Cutting Tool Insert

Application of petroleum based cutting fluids in machining operation may cause many problems such as eye burn and skin inflation etc. Vegetables oils are good alternative to overcome such issues. In this work, experiments were carried out to study the influence of coconut oil on the performance of single point cutting tool insert in turning operation. Three cutting conditions viz. dry, wet and coconut oil were considered to evaluate the tool wear. Results obtained from the experiments highlighted the advantages of coconut oil, a considerable reduction in flank wear, crater wear and auxiliary wear was observed in the turning operation.

Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

2007 ◽  
Author(s):  
Niniza S. P. Dlamini ◽  
Iakovos Sigalas ◽  
Andreas Koursaris
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Crater Wear ◽  
Compacted Graphite ◽  
Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

Influence of Tool Holder Material on Interfacial, Insert and Tool Holder Temperatures During Turning Operation of Gray Iron

2012 ◽  
Author(s):  
Almir K. Kaminise ◽  
Gilmar Guimaraes ◽  
Marcio B. Da Silva
Keyword(s):  
Temperature Distribution ◽  
Carbon Steel ◽  
Cutting Tool ◽  
Gray Iron ◽  
Cutting Fluid ◽  
Interface Temperature ◽  
Turning Operation ◽  
Tool Holder ◽  
Cutting Insert ◽  
Thermocouple Method

Usually studies related to machining temperature consider a system comprised of workpiece, chip and cutting tool, the effect of tool holder material is not taken in account. However, due to its physical properties, the tool holder material, usually carbon steel, has effect in the dissipation of the heat generated. This work studies the effect of the tool holder material on the temperature distribution during the turning operation of gray iron using cemented carbide cutting tool and without cutting fluid. Five tool holders were manufactured from materials with different heat conductivity: carbon steel, stainless steel, titanium, copper and bronze. Temperatures in eight different positions in the tool holder and cutting insert were measured. The average temperature at the chip tool interface was also measured using the tool-work thermocouple method. The results showed that the measured chip tool interface temperature was less affected by the tool holder material, although the temperature distribution at the cutting tool is highly affected.

PROCESSING AND CHARACTERIZATION OF ECO-FRIENDLY CUTTING FLUID WITH NANO ADDITIVES FOR TURNING OPERATION

2021 ◽  
pp. 2150057
Author(s):  
M. K. MARICHELVAM ◽  
S. SENTHIL MURUGAN ◽  
K. MAHESWARAN ◽  
D. SHYAMPRASAD VARMA
Keyword(s):  
Boric Acid ◽  
Environmental Sustainability ◽  
Coconut Oil ◽  
Cutting Fluid ◽  
Interface Temperature ◽  
Test Flash ◽  
Cutting Fluids ◽  
Machined Surface ◽  
Turning Operation

Machining quality depends on numerous factors such as speed, feed rate, quality of the materials, the cutting fluids used and so on. The quality of machining components can also be improved by using appropriate cutting fluids. In this study, the three different types of eco-friendly cutting fluids based on coconut oil with nano boric acid particles were synthesized with nanoadditives and characterized during the lathe-turning operation of mild steel. The obtained results were compared between the dry/plain turning (without the cutting fluid) and the turning with the cutting fluids like coconut oil and mineral oil with nanoparticles. In industries, a wide variety of cutting fluids are used; however, most of these cutting fluids are made up of synthetic materials which may affect the environment significantly. Hence, it is essential to develop eco-friendly cutting fluids for environmental sustainability. Here, the cutting fluids were characterized by the morphological study on nanoparticles (400[Formula: see text]nm) and the machined surface using scanning electron microscope (SEM), viscosity test, flash and fire point, surface roughness on machined part, tool tip-workpiece interface temperature, cutting force and flank wear measurement. The results showed that cutting fluids with 0.5% of boric acid had better performance.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Forces on a Worn Cutting Tool

1961 ◽  
Vol 83 (4) ◽  
pp. 505-509 ◽  
Author(s):  
H. T. McAdams ◽  
Paul Rosenthal
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Removal Rate ◽  
Single Point ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Land Area ◽  
Constant Depth ◽  
Feed Force ◽  
Stock Removal

The forces on a single-point cutting tool under conditions of progressive flank wear are analyzed under the assumptions of constant rake, friction, and shear angle. Relations between wear land area and stock removal rate are derived for the case of constant feed force. For the case of constant depth of cut, the relation between wear land area and feed force is developed.

scholarly journals Influence of Water-Miscible Cutting Fluids on Tool Wear Behavior of Different Coated HSS Tools in Hobbing

2018 ◽  
Vol 8 (2) ◽  
pp. 10 ◽  
Author(s):  
Hironori Matsuoka ◽  
Akio Kubo ◽  
Hajime Ono ◽  
Takahiro Ryu ◽  
Hua Qiu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Flank Wear ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Crater Wear ◽  
Coated Tools ◽  
Finished Surface ◽  
Influence Of Water ◽  
Tool Cutting

The present paper describes the influence of water-miscible cutting fluids on tool life (flank wear) and crater wear of various coated cutting tools and finished surface roughness, as compared with the cases of dry cutting and wet cutting using cutting oil in hobbing in an attempt to improve the working environment. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The following results were obtained. (1) In the case of an uncoated tool, cutting oil was more effective than dry cutting in reducing flank wear. Cutting oil and water-miscible cutting fluids were more effective in reducing flank wear than dry cutting using TiN- and TiAlN-coated tools. The use of water-miscible cutting fluids in conjunction with TiSiN- and AlCrSiN-coated tools prolongs tool life. (2) For all coated tools, the use of cutting oil or water-miscible cutting fluids were effective in reducing crater wear. Especially, water-miscible cutting fluids were effective for TiSiN- and AlCrSiN-coated tools. (3) Regarding the finished surface roughness, in the case of dry cutting, the finished surface roughness was similar for various types of coating films. When using cutting oil or a water-miscible cutting fluid, the finished surface roughness improved compared with dry cutting, independent of the type of coating film applied. The finished surface roughness obtained using water-miscible cutting fluid was approximately the same as or smaller than that obtained using cutting oil. (4) With respect to flank wear, crater wear, and finished surface roughness, the water-miscible cutting fluid of emulsion type containing a large amount of synthetic lubricating additives was suitable for the AlCrSiN-coated tool.

Experimental Study of Tool Wear Evolution during Turning Operation Based on DWT and RMS

2021 ◽  
Vol 406 ◽  
pp. 392-405
Author(s):  
Hamid Zaida ◽  
Abdelaziz Mahmoud Bouchelaghem ◽  
Seif Eddine Chehaidia
Keyword(s):  
Tool Wear ◽  
Wavelet Transforms ◽  
Cutting Tool ◽  
Flank Wear ◽  
Progressive Failure ◽  
Machining Process ◽  
Discrete Wavelet ◽  
Technical Requirement ◽  
Turning Operation ◽  
Work Material

In cutting process, the wear of the tool remains posed, it describes their progressive failure in regular operation. The tool wear phenomena is mainly caused by abrasion of hard particles, shearing of micro welds between tool and work-material and the exchange of particles between the tool and work material leading to a several forms of tool wear, however, we focused in this study on the frontal wear, also called wear on clearance surface or flank wear. For efficient use of cutting tool according to the technical requirement, the comprehension and the knowledge of the cutting tool wear evolution is necessary. In order to meet this indispensable need, the present paper proposes a two-step tool flank wear monitoring technique based on vibratory signals analysis during the turning operation using a P30 grade metal carbide tool and C45 (XC48) steel. Firstly, discrete wavelet transforms (DWT), has been used to decompose the signal and extract the information, then the scalar indicator Root Mean Square (RMS) value has been used to evaluate the cutting tool stability level. The proposed method offers the possibility to accurately predict break-in tool wear phase, accelerated tool wear phase and the stability period, in which a high quality machining process is guaranteed.

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