scholarly journals Machining of Injection Mould Materials for Different Cutting Flute in Low-Speed End Milling

2014 ◽  
Vol 564 ◽  
pp. 538-542
Author(s):  
Naain Shari ◽  
B.T. Hang Tuah bin Baharudin ◽  
Norsilawati Ngah ◽  
M.F.C. Ibrahim
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Cutting Tool ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Tools ◽  
End Mill ◽  
Injection Mould ◽  
Mould Material ◽  
Material Hardness

The complexity of mould shapes and the hardness of the mould material contribute to difficulties in machining. Examination of the capability of atypeof cutting tool (Tungsten Carbide Ball Nose) towards machining mould material that is usually used in Injection Moulding Industries. Following this, an experimental work was detailed relating to the use of ball nose end mill to machine hardened injection mould materials (up to 62 HRC).Surface roughness, surface topography and tool wear data were presented. The relationships of all these three properties respect to each other were also investigated. By machining these materials (Stavax, Stainless Steel, DF3 and XW5), a major wear occur on cutting tool which is called flank wear. Theflank wear is increased by increasing the hardness of the material used. This fact was supported by the result obtained, in which the surface roughness increases when the material hardness increased. Surface topography isdescribed through wavy marks and surface tearing. For 2 and 4-flute cutting tools, the waviness phenomenal ondecreases when material hardness was increased. Meanwhile, for surface tearing, the rate of occurrence is proportional to the increment of the material hardness.

The Predictive Model of Surface Roughness and Searching System in Database for Cutting Tool Grinding

2009 ◽  
Vol 626-627 ◽  
pp. 11-16 ◽  
Author(s):  
Yung Cheng Wang ◽  
Chen Hsiang Chen ◽  
Bean Yin Lee
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Rapid Development ◽  
Cutting Tools ◽  
Experiment Planning ◽  
Grinding Wheel ◽  
End Mill ◽  
Grinding Parameters ◽  
End Mills ◽  
Tool Grinding

Due to the rapid development in recent cutting technology, demands for different types of precise cutting tools become increasingly complicated. Since the design and grinding of end-mills are the last and the most important processing for cutting tools. The geometrical accuracy and the cutting performance of an end-mill depend essentially on the grinding. However, the complicated geometry of an end-mill will be ground by the specific software of CAD/CAM on the 5-axis CNC tool grinding machine. The precision of end-mill grinder will be determined by the performance of 5-axis CNC tool grinder and setting of grinding parameters. Three regulation factors for grinding are grit size of the diamond grinding wheel, grinding speed and the feeding speed. The variable ranges of each parameter can be divided in large, medium and small interval. In this study for an end-mill with fixed geometrical profile, a series of different grinding parameters have been utilized by the 33 factorial experiment planning. And tool grinding experiments for the rod material specification of tungsten carbide have been performed by 5-axis CNC tool grinder. After grinding, surface roughness of tools will be measured. The reliability and precision of the end-mill grinding can be enhanced by the prediction model of polynomial network for surface roughness of end-mills. Besides, the database system for cutting tool has benn established. Totally 4802 data were constructed in the relational database according to the characteristics of tools.

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

2017 ◽  
Vol 16 (03) ◽  
pp. 237-261 ◽  
Author(s):  
T. Sampath Kumar ◽  
S. Balasivanandha Prabu ◽  
T. Sorna Kumar
Keyword(s):  
Surface Roughness ◽  
Alloy Steel ◽  
Surface Finish ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Coated Carbide

In the present work, the performances of TiAlN-, AlCrN- and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN- and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi’s approach is used to obtain the best turning parameters, namely cutting speed ([Formula: see text]), feed rate ([Formula: see text]) and depth of cut ([Formula: see text]), in order to have a better surface finish and minimum tool flank wear. An orthogonal array (L[Formula: see text] was used to conduct the experiments. The results show that the AlCrN/TiAlN-coated cutting tool provided a much better surface finish and minimum tool flank wear. The minimum tool flank wear and minimum surface roughness were obtained using AlCrN/TiAlN-coated tools, when [Formula: see text][Formula: see text]m/min, [Formula: see text][Formula: see text]mm/rev and [Formula: see text][Formula: see text]mm.

scholarly journals Integrating object detection and image segmentation for detecting the tool wear area on stitched image

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Wan-Ju Lin ◽  
Jian-Wen Chen ◽  
Jian-Ping Jhuang ◽  
Meng-Shiun Tsai ◽  
Che-Lun Hung ◽  
...  
Keyword(s):  
Tool Wear ◽  
Template Matching ◽  
Cutting Tool ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Tools ◽  
Milling Process ◽  
Wear Area ◽  
Learning Techniques ◽  
The Times

AbstractFlank wear is the most common wear that happens in the end milling process. However, the process of detecting the flank wear is cumbersome. To achieve comprehensively automatic detecting the flank wear area of the spiral end milling cutter, this study proposed a novel flank wear detection method of combining the template matching and deep learning techniques to expand the curved surface images into panorama images, which is more available to detect the flank wear areas without choosing a specific position of cutting tool image. You Only Look Once v4 model was employed to automatically detect the range of cutting tips. Then, popular segmentation models, namely, U-Net, Segnet and Autoencoder were used to extract the areas of the tool flank wear. To evaluate the segmenting performance among these models, U-Net model obtained the best maximum dice coefficient score with 0.93. Moreover, the predicting wear areas of the U-Net model is presented in the trend figure, which can determine the times of the tool change depend on the curve of the tool wear. Overall, the experiments have shown that the proposed methods can effectively extract the tool wear regions of the spiral cutting tool. With the developed system, users can obtain detailed information about the cutting tool before being worn severely to change the cutting tools in advance.

Effect of Tool Tilting Angle on Tool Wear and Surface Roughness in Micro Ball End Milling

2011 ◽  
Vol 325 ◽  
pp. 606-611 ◽  
Author(s):  
Kazuya Hamaguchi ◽  
Yuji Kagata ◽  
Hiroo Shizuka ◽  
Koichi Okuda
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Depth Of Cut ◽  
End Mill ◽  
Ball End Mill ◽  
Ball End Milling ◽  
Tilting Angle ◽  
Radial Depth

This paper describes the effect of the tool tilting angle on the tool wear and the surface roughness in micro ball end milling. The cutting tests of hardened stainless steel were carried out by using of the micro ball end mill with radius of 100mm under the conditions of tilting angle from 0° to 45°. The spindle speed was fixed in a constant of 120,000 min-1. The feed per tooth, axial depth of cut and radial depth of cut were also fixed. The flank wear, the surface roughness and the cutting force were investigated. As a result, the maximum width of flank wear of the micro ball end mill tended to decrease with an increase in the tilting angle of spindle. The surface roughness became almost constant not depending on the tilting angle of the spindle.

Effect of Variable Pitch on Cutting Temperature, Cutting Forces and Surface Roughness Using Nitico30 Cutting Tool when End Milling of Stainless Steel 316L

2017 ◽  
Vol 909 ◽  
pp. 50-55
Author(s):  
Afiff Latif ◽  
Mohd Rasidi Ibrahim ◽  
Mohammad Sukri Mustapa ◽  
Noor Hakim Rafai ◽  
Charles Prakash
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Stainless Steel 316L ◽  
Variable Pitch

In this paper, a series of milling tests were carried out in order to identify the effects of variable pitch on cutting temperature, cutting force and surface roughness while end milling the stainless steel 316L using Nitico30 and conventional cutting tools. Slot-milling operations were conducted. The value of feed rate were choose between the range recommended by the manufactured for the both conventional and Nitico30 cutting tool. The effect of variable pitch on cutting temperature, cutting forces and surface roughness were discussed. Results showed that the cutting temperature increase with the increase of feed rate for both cutting tool. Further increasing the speed of feed rate, the cutting forces also gradually increase for both cutting tool. However, the comparison between both cutting tools, it was found that the cutting temperature, cutting force and surface roughness improve about 47.8%, 37.5% and 17.6% respectively for Nitico30 cutting tool.

scholarly journals Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1783
Author(s):  
Hamza A. Al-Tameemi ◽  
Thamir Al-Dulaimi ◽  
Michael Oluwatobiloba Awe ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Good Practice ◽  
Cutting Tools ◽  
Statistical Design ◽  
Cutting Parameters ◽  
Statistical Design Of Experiments ◽  
Hole Quality ◽  
Coated Tools ◽  
Tool Coating

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

scholarly journals Remaining Useful Life Prediction of Cutting Tools Using an Inverse Gaussian Process Model

2021 ◽  
Vol 11 (11) ◽  
pp. 5011
Author(s):  
Yuanxing Huang ◽  
Zhiyuan Lu ◽  
Wei Dai ◽  
Weifang Zhang ◽  
Bin Wang
Keyword(s):  
Surface Roughness ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Remaining Useful Life ◽  
Model Parameters ◽  
Inverse Gaussian ◽  
Wear Process ◽  
Useful Life ◽  
Dynamic Wear

In manufacturing, cutting tools gradually wear out during the cutting process and decrease in cutting precision. A cutting tool has to be replaced if its degradation exceeds a certain threshold, which is determined by the required cutting precision. To effectively schedule production and maintenance actions, it is vital to model the wear process of cutting tools and predict their remaining useful life (RUL). However, it is difficult to determine the RUL of cutting tools with cutting precision as a failure criterion, as cutting precision is not directly measurable. This paper proposed a RUL prediction method for a cutting tool, developed based on a degradation model, with the roughness of the cutting surface as a failure criterion. The surface roughness was linked to the wearing process of a cutting tool through a random threshold, and accounts for the impact of the dynamic working environment and variable materials of working pieces. The wear process is modeled using a random-effects inverse Gaussian (IG) process. The degradation rate is assumed to be unit-specific, considering the dynamic wear mechanism and a heterogeneous population. To adaptively update the model parameters for online RUL prediction, an expectation–maximization (EM) algorithm has been developed. The proposed method is illustrated using an example study. The experiments were performed on specimens of 7109 aluminum alloy by milling in the normalized state. The results reveal that the proposed method effectively evaluates the RUL of cutting tools according to the specified surface roughness, therefore improving cutting quality and efficiency.

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.

Surface Roughness Analysis for Radius End Mill in Cross Feed Direction Both Contour and Scanning Line Machinings

2020 ◽  
Author(s):  
Hirohisa Narita
Keyword(s):  
Surface Roughness ◽  
Inclination Angle ◽  
End Milling ◽  
Contour Line ◽  
End Mill ◽  
Good Surface ◽  
Corner Radius ◽  
Feed Direction ◽  
Scanning Line ◽  
Influence Degree

Abstract An optimum experimental condition, which realize good surface roughness in cross direction both contour and scanning lines, for radius end mill against some inclined surfaces is obtained and some features is these cutting processes is discussed in this paper. The optimum experimental condition, which consists of cutting type (or feed direction), spindle speed, feed rate, depth of immersion, inclination angle, corner radius of end mill and cross feed, is obtained and the influence degree of these parameters is calculated by using Taguchi method. The experiment is carried out based on L18 orthogonal array. Based on the influence degree and geometric contact status due to unique shape of radius end mill, some feature of radius end milling is introduced. As a result of the contour line machining, a scallop height is very influenced by the inclination angle and the corner radius, and surface machined by bottom edge must not be remained. Regarding the scanning line machining, “go-up” is good for the feed direction. Big corner radius is also suitable because side edge does not contact to workpiece. In other words, the cutting force in radial direction becomes small. Furthermore, the surface roughness of the scanning line machining is smaller than the one of the contour line machining.

Development of the cBN Electroplated End-Mill for High Precision Machining of CFRP

2020 ◽  
Author(s):  
Shinnosuke Yamashita ◽  
Tatsuya Furuki ◽  
Hiroyuki Kousaka ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Drop Out ◽  
End Mill ◽  
Machined Surface ◽  
Side Milling ◽  
Reinforced Plastics ◽  
Milled Surface ◽  
Grinding Conditions ◽  
Grinding Tool

Abstract Recently, the demand of carbon fiber reinforced plastics (CFRP) has been rapidly increased in various fields. In most cases, CFRP products requires a finish machining like cutting or grinding. In the case of an end-milling, burrs and uncut fibers are easy to occur. On the other hand, a precise machined surface and edge will be able to obtain by using the grinding tool. Therefore, this research has been developed a novel the cBN electroplated end-mill that combined end-mill and grinding tool. In this report, the effectiveness of developed tool was investigated. First, the developed tool cut the CFRP with side milling. As the result, the cBN abrasives that were fixed on the outer surface of developed tool did not drop out. Next, the end-milled surface of CFRP was ground with the developed tool under several grinding conditions based on the Design of Experiment. Consequently, the optimum grinding condition that can obtain the sharp edge which does not have burrs and uncut fibers was found. However, surface roughness was not good enough. Thus, an oscillating grinding was applied. In addition, the theoretical surface roughness formula in case using the developed tool was formularized. As the result, the required surface roughness in the airplane field was obtained.

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