On-Line Monitoring of Drill Wear Using Air-Coupled Audio Microphone when Drilling Composite Materials

2014 ◽  
Vol 590 ◽  
pp. 645-650 ◽  
Author(s):  
Eshetu D. Eneyew ◽  
Mamidala Ramulu
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Flank Wear ◽  
High Speed Steel ◽  
High Rate ◽  
Drilling Process ◽  
Monitoring Method ◽  
On Line

The condition of the cutting tool when drilling composite materials is the controlling factor for the surface integrity of hole produced. The high rate of tool wear when drilling composite materials makes finding a way to monitor the condition of the cutting tool without interrupting the drilling process a great necessity. Inspecting the condition of the drill between or during the drilling process is not practical or economical. In an attempt to tackle this problem, a new approach of on-line tool wear monitoring method using an air-coupled audio microphone is proposed. An experimental investigation was conducted on multi-directional carbon fiber reinforced plastic (CFRP) composite material using a high speed steel (HSS) drill. The result shows that, the amplitude of the acoustic signal from the microphone decreases when the amount of flank wear increases and the amplitude of thrust force and torque increases with the increase of the flank wear. This result demonstrates that the proposed approach can be used as an effective and economical tool for on-line monitoring of cutting tool 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.

Optimization of Parameter for HSS Tool Wear by Using Taguchi Method and Finite Element Method

2013 ◽  
Vol 315 ◽  
pp. 151-155
Author(s):  
M.R. Ibrahim ◽  
A.R. Abd. Kadir ◽  
M.S. Omar ◽  
S. Sulaiman ◽  
M.H. Osman
Keyword(s):  
Tool Wear ◽  
Taguchi Method ◽  
Surface Treatment ◽  
High Speed ◽  
Flank Wear ◽  
Simulation Analysis ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Coated Surface

This paper presents the combination between the simulation analysis of FEM (DFORM 3D) and Taguchi method approach. The Taguchi method was used to find the optimize parameter design contribute to Flank wear. The parameters were evaluated are coated surface treatment, cutting speed and feed rate. The Usuis model carried out to measure the flank wear size. Furthermore, ANOVA analysis was used out to identify the influence factors contribute to tool wear in the signal to noise ratio. The experiments were conducted on AL6061 by using High Speed Steel Tool (HSS) in face milling cutting. It shown that, the coated surface treatment is the most significant parameter which can reduce the tool wear value.

Cutting-tool wear and hardening of high-speed steel by local electrospark coating application

2009 ◽  
Vol 29 (4) ◽  
pp. 419-422 ◽  
Author(s):  
V. N. Gadalov ◽  
R. E. Abashkin ◽  
Yu. V. Boldyrev ◽  
E. F. Balabaeva ◽  
A. I. Lytkin
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
High Speed Steel ◽  
Electrospark Coating ◽  
Coating Application ◽  
Cutting Tool Wear

Effect of residual elements on the machinability of leaded free machining steels

1980 ◽  
Vol 295 (1413) ◽  
pp. 87-88 ◽  
Keyword(s):  
Wear Rate ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Low Carbon ◽  
Wear Rates

The machinability of a material can be defined in terms of the wear rate of the cutting tool used to machine the material. The lower the tool wear rate or the greater the tool life the better the machinability. The wear processes of cutting tools are complicated, but recent work has shown that cutting tool wear rates during machining can be directly related to tool material wear rates when rubbing in a modified crossed cylinder wear experiment (Mills & Akhtar 1975). The wear of cutting tools can be simulated by simple experiments. Here I present results on the effect of total residual levels in leaded low carbon free machining steels on the tool life of M2 high speed steel. The results will be discussed in terms of a simple wear model.

scholarly journals Neural Network Monitoring Strategy of Cutting Tool Wear of Horizontal High Speed Milling

2014 ◽  
Vol 565 ◽  
pp. 46-52
Author(s):  
Kious Mecheri ◽  
Benhorma Hadj Aissa ◽  
Ameur Aissa ◽  
Hadjadj Abdechafik
Keyword(s):  
Neural Network ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Machining Process ◽  
Physical Parameters ◽  
Cutting Tool Wear ◽  
On Line

The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc.... In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions

Determination of tool wear and chip formation in drilling process of AISI 1045 material using plasma-nitrided high-speed steel drill bits

2015 ◽  
Vol 231 (10) ◽  
pp. 1725-1734 ◽  
Author(s):  
İsmail Ucun ◽  
Serdar Kaplan
Keyword(s):  
Mechanical Properties ◽  
Tool Wear ◽  
Chip Formation ◽  
High Speed ◽  
Plasma Nitriding ◽  
High Speed Steel ◽  
Drilling Process ◽  
Drill Bits ◽  
Aisi 1045 ◽  
Steel Drill

In this study, tool wear and chip formation during the drilling process of AISI 1045 material using plasma-nitrided high-speed steel drill bits were experimentally investigated. Two uncoated and plasma-nitrided drill types were used in the experiments. First, commercial drill bits were subjected to the plasma nitriding process. Following this, the drilling processes were carried out at various feed rates and cutting speeds. A sensitive computer numerical control machine was used in the experiments. Tool wear was determined using scanning electron microscopy and chips obtained from the drilling process were observed under microscopy. Finally, the relationship between the chip cross section and tool wear was determined using statistical analysis. It was concluded that the mechanical properties of uncoated high-speed steel drill bits improve significantly through the plasma nitriding process. Less tool wear and a good chip formation were observed with the improvement of the mechanical properties. It was determined that there is a relationship between the chip section and wear.

Machinability of Fiber-Reinforced Thermoplastics in Drilling

1993 ◽  
Vol 115 (1) ◽  
pp. 146-149 ◽  
Author(s):  
H. Hocheng ◽  
H. Y. Puw
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Fiber Reinforced ◽  
Heat Accumulation ◽  
Edge Quality ◽  
Carbon Fiber Reinforced

Polymer-based composite materials are used in a variety of industry. Recently, thermoplastic polymer suitable for the resinous matrix in carbon fiber-reinforced composites has been introduced for lower material and processing costs, improved damage tolerance and higher moisture resistance. The successful use of this material requires sophisticated production technology, however little reference of machining of thermoplastics composites can be found. The existing published results are almost exclusively for epoxy-based composite materials showing difficulty in avoiding poor finish, serious tool wear and delamination at hole entrance and exit due to the brittle material response to machining. Thermoplastics-based composite materials possesses better machinability. The current work reveals the machinability of an example of carbon fiber-reinforced ABS (Acrylonitrile Butadiene Styrene) in drilling compared to representative metals and thermoset-based composites. The observation of chips reveals that considerable plastic deformation is involved. Compared to the chip formation of thermoset plastics, it contributes to the improved edge quality in drilling. The edge quality is generally fine except in the case of concentrated heat accumulation at tool lips, which is generated by high cutting speed and low feed rate. Plastics tend to be extruded out of the edge rather than neatly cut. The average surface roughness along hole walls in commonly below one micron for all sets of cutting conditions in the experiment, values between 0.3 and 0.6 microns are typical. The high speed steel drill presents only minor tool wear during the tests. Based on these results, one concludes that the carbon fiber-reinforced ABS demonstrates good machinability in drilling.

scholarly journals Optimization of Input Parameters with Carbide Inserts and HSS Tool on CNC Turning of EN19 Steel

2019 ◽  
Vol 8 (12) ◽  
pp. 3869-3875
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Cutting Tool ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Process ◽  
Steel Tool ◽  
Carbide Inserts

This paper deals with the experimental investigation and testing on a single point cutting tool with carbide inserts and high speed steel tool. Cutting tool has to be strong enough to withstand the wear resistance. It is to be proved that carbide inserts have better performance than HSS tools on machining operation. Components with higher surface quality, higher material removal rate in less time and lower tool wear is only possible by carbide insert tools. The tool material selected for this experiment are cemented & tungsten carbide inserts along with high speed steel tool on machining medium carbon steel EN19. The complete machining process is performed on cnc lathe machine Hence the intention of this project is to minimize the surface roughness, tool wear, machining time and increasing the material removal rate. Taguchi’s L9 orthogonal array is favor for this investigation work. The result obtained in this project can be further used for optimizing the process parameters there by optimized results helps the operator to improve the quality as well as production rate.

scholarly journals An experimental investigation of the effects of point angle on the high-speed steel drills performance in drilling

2018 ◽  
Vol 51 (9-10) ◽  
pp. 417-430 ◽  
Author(s):  
Zülküf Demir
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Cutting Edge ◽  
Drilling Process ◽  
Cutting Speeds

The differences in the cutting speed are a serious problem along the cutting edge of the drill, in drilling operations. This problem can partly be solved reducing the length of the cutting edge via changing the drill point angle. In addition, in this study, the effect of point angle, feed rate, and cutting speed on drilling is investigated. For identifying the optimum cutting parameters, AISI 1050 steel alloy was selected as the experimental specimen, these specimen were pre-drilled 5 mm in diameter due to eliminating the effect of the chisel edge. In the experiments, the holes were drilled only at a depth of 10 mm in order not to give any harm to the dynamometer while measuring thrust force. For this aim, in drilling process, drills with point angle of 100°, 118°, 136°, 154°, and 172° were selected. In conclusion, the thrust force, the tool wear, and the surface roughness linearly decreased with increasing point angles due to less removal chip area, in per revolve of the tool. However, the thrust force, the tool wear, and the surface roughness were adversely affected at higher feed rates and lower cutting speeds. The hole dimensional accuracy decreased at lower feed rates and cutting speeds but at higher point angles and concurrently at higher feed rates but lower point angles and cutting speeds. However, the hole dimensional accuracy showed more decisiveness at 118° than other point angles, while the highest dimensional accuracy values recorded at 136° point angle, at higher cutting speeds.

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