Using Infrared Thermograph of Chip Temperature to Monitor Cutting Edge Performance

2015 ◽  
Vol 789-790 ◽  
pp. 549-553 ◽  
Author(s):  
M.S. Alajmi ◽  
S.E. Oraby
Keyword(s):  
Cutting Speed ◽  
Cutting Edge ◽  
Thermal Camera ◽  
Sem Micrographs ◽  
Chip Temperature ◽  
Edge Wear ◽  
Lower Heat ◽  
Infrared Thermograph ◽  
Carbide Inserts

Recently, the need arises for new machining inprocess techniques to monitor and/or control machining systems. Due to the introduction of digital thermal noncontact cameras, it becomes possible to assess the chip temperature hence, to evaluate the possible relation between edge performance and variation within such temperature. A noncontact infrared thermal camera is mounted on a turning lathe carriage to record the cutting temperatures as cutting speed and feed vary using both coated and uncoated carbide inserts. Temperatures gradient, along with the relevant SEM micrographs, are analyzed for possible correlation with both regular and irregular cutting edge deformation. While cutting speed proved not to be an influential parameter on the depicted temperatures, feed increase tends to lower cutting temperatures. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation develop.

On the Influence of the Speed-Feed Interaction on the Wear Rate and Life of Multiple Coated Carbide Inserts Considering Rough Turning Process

2014 ◽  
Vol 575 ◽  
pp. 431-436 ◽  
Author(s):  
M.S. Alajmi ◽  
S.E. Oraby
Keyword(s):  
Wear Rate ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Cutting Edge ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Edge Wear ◽  
The Impact ◽  
Rough Turning ◽  
Coated Carbide

The impact of the cutting parameters; speed, feed, and depth of cut on the wear and the life of the cutting edge has long been a matter of debate among researchers. The cutting speed has long been agreed to have a prime influence in such a way that increasing speed leads to higher wear rate. Depth of cut has been concluded by majority of studies to have insignificant or negligible impact on edge wear and deformation. Despite its long established influence on the roughness of the machined surface, the effect of cutting feed on edge wear and deformation still requires more explanation. Cutting feed is a crucial parameter governing the product surface finish and dimensional accuracy and, therefore, its attitude during machining should be fully understood. This study presents experimental and modeling approach to detect the feed-wear functional interrelation considering various domains of the cutting speed. Results showed that the impact of the cutting feed is firmly associated with the level of cutting speed employed. Speed-feed interaction proved to be responsible for the performance of the cutting edge during machining.

Cutting edge wear in high-speed stainless steel end milling

2021 ◽  
Author(s):  
Mohammad Malekan ◽  
Camilla D. Bloch-Jensen ◽  
Maryam Alizadeh Zolbin ◽  
Klaus B. Ørskov ◽  
Henrik M. Jensen ◽  
...  
Keyword(s):  
Stainless Steel ◽  
High Speed ◽  
End Milling ◽  
Cutting Edge ◽  
Edge Wear

What Sound Can Be Expected From a Worn Tool?

1969 ◽  
Vol 91 (3) ◽  
pp. 525-534 ◽  
Author(s):  
E. J. Weller ◽  
H. M. Schrier ◽  
Bjorn Weichbrodt
Keyword(s):  
Machine Tool ◽  
Detection System ◽  
Cutting Edge ◽  
Cemented Carbide ◽  
Electronic Unit ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Edge Wear ◽  
Sonic Detection ◽  
1045 Steel

This paper describes an electronic-mechanical system which utilizes sonic signals to detect the degree of cutting edge wear in metalworking tools and automatically trigger a cutting edge change. A packaged electronic unit reads out sonic vibrations from an instrumented machine-tool workpiece cutting-tool system to determine degree of cutting edge wear during a turning cut. At a predetermined comparative sonic ratio, the electronic unit commands stoppage of the machine tool feed, retraction of the tool and automatic index of the cemented carbide insert to the next good cutting edge. The latter function is performed by a prototype mechanical device. The paper describes the system and cites data generated during use of the sonic detection system with five grades of cemented carbide cutting AISI 1045 steel. Results under varying cutting conditions are reported. The authors speculate on the possibility of combining such a wear detection and cutting edge indexing arrangement with a computer to provide a complete system for optimum productivity and economy in a completely automatic operation.

Wear Behavior of Carbide Inserts in Face Milling TA19 Alloy

2012 ◽  
Vol 426 ◽  
pp. 339-343 ◽  
Author(s):  
Qiu Lin Niu ◽  
X.J. Cai ◽  
Zhi Qiang Liu ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Titanium Alloy ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Aircraft Engine ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Crater Wear ◽  
Stable Conditions ◽  
Carbide Inserts

As a typical high strength material, titanium alloy Ti-6Al-2Sn-4Zr- 2Mo-0.1Si (TA19) is used to manufacturing the compressor power-brake of aircraft engine and the aircraft skin. All the machining experiments were carried out on a CNC-milling center under the stable conditions of cutting speed, feed rate, and depth of cut. The performance and wear mechanisms of coated- and uncoated carbide tools have been investigated in this paper to evaluate the machinability of TA19 in face milling. The three tools used were PVD-TiN+TiAlN, CVD-TiN+Al2O3+TiCN and uncoated carbide inserts. The results indicated that PVD coating had the best performance than other tool materials in milling titanium alloy TA19, and the cutting force and the wear value were the smallest than that for CVD-coated and uncoated tools. The failure types of PVD-, CVD- and uncoated inserts were the crater wear and micro tipping; the crater wear and tipping; tipping. Abrasive wear and adherent wear were the predominant mechanism of PVD-TiN+TiAlN carbide insert in face milling TA19 alloy. For CVD- and uncoated carbide, adherent wear was predominant.

scholarly journals Advances in efficiency in the groove milling of aluminium EN AW 2024-T3 with zig-zag and trochoidal strategies

2021 ◽  
Vol 1193 (1) ◽  
pp. 012005
Author(s):  
O Rodríguez ◽  
P E Romero ◽  
E Molero ◽  
G Guerrero
Keyword(s):  
Energy Consumption ◽  
Removal Rate ◽  
Cutting Speed ◽  
Machining Time ◽  
Tool Performance ◽  
Discontinuous Cutting ◽  
Edge Wear ◽  
Factorial Design Of Experiments ◽  
Efficient Manufacturing ◽  
Manufacturing Time

Abstract Manufacturing process engineers must continually take decisions to make the processes efficient. Manufacturing time, surface finish and energy consumption are aspects to be optimized in machining. This study analyzes the efficiency of groove milling in milling aluminum alloys EN AW 2024-T3 with zig-zag and trochoidal strategies. Dynamic milling is designed to maximize the removal rate and optimize the tool performance. This generates a discontinuous cutting with minimum of heat reducing build-up with an optimal chip removal minimizing cutting edge wear. The influence of lateral pitch, feed per tooth, cutting speed and coolant pressure has been analyzed. The depth of curt has been adapted for each strategy and tool type. The study was proposed through a factorial design of experiments by the Taguchi method. The machining time (T) and energy consumption (EC) show a strong influence of the lateral step (a e ) in conventional milling. A similar level of influence appears with the feed per tooth (f z ) on the trochoidal. The roughness (Ra) is more influenced by cutting speed (V c ) for conventional milling and by feed per tooth (f z ) and lateral pitch (a e ) for the trochoidal.

Machining Performance of PM Material Containing MnX Additives

1999 ◽  
Author(s):  
S. Barnes ◽  
M. J. Nash ◽  
M. H. Lim
Keyword(s):  
Powder Metallurgy ◽  
Cutting Speed ◽  
Superior Performance ◽  
Metal Powders ◽  
Machining Performance ◽  
Basic Composition ◽  
The Third ◽  
Trade Name ◽  
Carbide Inserts ◽  
Cutting Speeds

Abstract Improvements in the machining performance of ferrous powder metallurgy (PM) materials has recently been reported by one of the main manufacturers of metal powders. This improvement in machinability reportedly being achieved by the addition of a new free-machining additive which is marketed under the trade name of “MnX”. The work reported here, investigated this claim by comparing the performance of three PM materials with the same basic composition but different free-machining additives. The first material contained no free-machining additive, the second, contained the conventional manganese sulphide (MnS) additive and the third contained the new MnX additive. A turning operation was used to compare the performance of the three materials at cutting speeds in the range of 100–250 m/min using titanium nitride (TiN) coated UE6005 carbide inserts. The relative performance of the three materials was compared by measuring cutting forces, tool wear and the surface finish produced on the workpiece. It was found that at all cutting speeds investigated, the material containing MnX gave a superior performance. However, at higher cutting speeds the superiority of the material containing MnX was much more significant. In contrast, at the lowest cutting speed of 100 m/min, it was found that although the material containing MnX continued to exhibit the best performance, the differences between the three materials were substantially reduced and the material containing no free machining additive actually generated slightly less wear than the material containing MnS. The results therefore confirm that the new MnX additive is superior to the conventional MnS additive. However, this work has also demonstrated that relatively high cutting speeds are needed in order to obtain optimum benefits from the new additive.

The Dependency of the Tool Life on the Cutting Speed at the Investigation of the Tool with Specific Geometry

2012 ◽  
Vol 622-623 ◽  
pp. 347-351 ◽  
Author(s):  
Katarina Monkova ◽  
Sergej Hloch
Keyword(s):  
Regression Analysis ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Specific Geometry ◽  
Graphical Presentation

The aim of the paper is to find the dependency of tool life on the cutting speed at investigation of two selected tools with linear cutting edge not parallel with the workpiece axis. The tools differ in their geometry. Conditions of experiments, used equipments and some problems, which are necessary to solve from the standpoint of machining technology with regard to tools are described in the article, too. The experimental obtained data were statistical processed by the method of regression analysis. The results are arranged into the graphical presentation, which enables the comparison of tool life at the same cutting speed and consequently the choice of the most suitable geometry of tool at the machining in specific conditions.

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