Monitoring of Wear Land Width of Diamond Tool Cutting Edge with Large Nose Radius in Ultra-Precision Cutting Using Static Cutting Forces

2014 ◽  
Vol 1017 ◽  
pp. 696-702
Author(s):  
Eiji Kondo ◽  
Ryuichi Iwamoto ◽  
Yuya Kobaru
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Diamond Tool ◽  
Flank Wear ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Single Crystal Diamond ◽  
Ultra Precision ◽  
Land Width

Large wear of diamond tools for ultra-precision cutting of soft metals deteriorates quality of machined surface, and the worn tools have to be replaced with new tools when the tool wear reaches limited wear land width of cutting edge generating finished surface. However, it is difficult to predict the tool life since all cutting tools have individual tool life. Therefore, the purpose of this study is to estimate wear land width of cutting edge of a single crystal diamond tool having large nose radius by using static cutting forces during machining. As a result of the cutting tests and measurements, it was found that the ratio of thrust force to principal force had good relation with the ratio of flank wear land area to cutting cross section area. Furthermore, according to some detailed observation of flank wear, width of flank wear land was greatly related to uncut chip thickness obtained under different cutting conditions and it was found that width of flank wear land could be estimated by measured static cutting forces and cutting conditions.

Prediction of Chip Flow Direction and Cutting Forces in Oblique Machining with Nose Radius Tools

1995 ◽  
Vol 209 (4) ◽  
pp. 305-315 ◽  
Author(s):  
J A Arsecularatne ◽  
P Mathew ◽  
P L B Oxley
Keyword(s):  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Chip Flow ◽  
Wide Range ◽  
Predicted Values ◽  
Edge Based

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and the cutting conditions, namely feed and depth of cut. By defining an equivalent cutting edge based on the chip flow direction it is then shown how cutting forces can be predicted given the work material's flow stress and thermal properties. A comparison between experimental results obtained from bar turning tests and predicted values for a wide range of tool geometries and cutting conditions shows good agreement.

Machining nickel base superalloys: Inconel 718

1998 ◽  
Vol 212 (3) ◽  
pp. 195-206 ◽  
Author(s):  
I A Choudhury ◽  
M A El-Baradie
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Coated Tools ◽  
Nickel Base ◽  
Better Than

A series of machining experiments of Inconel 718 has been carried out using coated and uncoated carbides. The paper describes the effects of cutting variables (speed, feed and depth of cut) on cutting forces and tool life. Carbide tools in the form of 80° rhomboid shaped inserts without any chip breaker have been used at different cutting conditions. The machining parameters have been optimized by measuring cutting forces. Flank wear was considered as the criterion for tool life. A comparison between the uncoated and coated tools has been made using the Taylor's tool life exponents of speed, feed and depth of cut. The tool life of coated tools was not found to be better than that of the uncoated tools.

Prediction of Chip Flow Direction, Cutting Forces and Surface Roughness in Finish Turning

1998 ◽  
Vol 120 (1) ◽  
pp. 1-12 ◽  
Author(s):  
J. A. Arsecularatne ◽  
R. F. Fowle ◽  
P. Mathew
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
Flow Direction ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Chip Flow ◽  
Edge Based ◽  
Tool Cutting ◽  
Good Agreement

A method is described for calculating the chip flow direction in terms of the tool cutting edge geometry and cutting conditions. By defining an equivalent cutting edge based on the chip flow direction it is shown how cutting forces can be predicted under finishing conditions when the work material’s flow stress and thermal properties are known. A comparison between predicted and experimental results obtained for a range of tool geometries and cutting conditions shows good agreement. Surface roughness Ra values measured in the tests are compared with the theoretical values determined from the nose radius and feed.

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%.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

scholarly journals Simulation and Experimental Study on the Surface Generation Mechanism of Cu Alloys in Ultra-Precision Diamond Turning

Micromachines ◽  
2019 ◽  
Vol 10 (9) ◽  
pp. 573
Author(s):  
Zhang ◽  
Guo ◽  
Chen ◽  
Fu ◽  
Zhao
Keyword(s):  
Tool Wear ◽  
Diamond Tool ◽  
Surface Characteristics ◽  
Diamond Turning ◽  
Generation Mechanism ◽  
Surface Generation ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cu Alloys ◽  
Ultra Precision

The surface generation mechanism of the Cu alloys in ultra-precision diamond turning is investigated by both simulation and experimental methods, where the effects of the cutting parameters on the surface characteristics are explored, including the workpiece spindle speed, the cutting depth, the feed rate and the nose radius of the diamond tool. To verify the built model, the cutting experiments are conducted at selected parameters, where the causes of the error between the simulation and the machining results are analyzed, including the effects of the materials microstructure and the diamond tool wear. In addition, the nanometric surface characteristics of the Cu alloys after the diamond turning are identified, including the finer scratching grooves caused by the tool wear, the formation of the surface burs and the adhesion of graphite. The results show that the built model can be basically used to predict the surface topography for the selection of the appropriate machining parameters in the ultra-precision diamond turning process.

scholarly journals Performance of Near Dry Hard Machining Through Pressurised Air Water Mixture Spray Impingement Cooling Environment

2019 ◽  
Vol 16 (1) ◽  
pp. 6108-6133
Author(s):  
R. Kumar ◽  
A.K. Sahoo ◽  
P.C. Mishra ◽  
R.K. Das
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Water Mixture ◽  
Impingement Cooling ◽  
Aisi D2 ◽  
Spray Impingement

The present paper emphasizes on experimental investigation, mathematical modelling, optimisation, tool life and cost analysis during machining of AISI D2 (heat treated) (55±1 HRC) steel using uncoated carbide tool through a novel method under spray impingement cooling environment. Taguchi based L16 orthogonal array was utilised to conduct the experiments. Analysis of variance with 95% confidence level shows that the feed and depth of cut, are the most compelling factor towards surface roughness as well as chip reduction coefficient whereas cutting speed is the utmost compelling feature associated to flank wear as well as chip-tool interface temperature. Optimised result is identified as v1-f1-d1 (machining speed of 63 m/min; cutting feed of 0.04 mm/rev and depth of cut of 0.1 mm) based on grey relational analysis and tool life is found to be 15 minutes at optimised cutting conditions. Flank wear due to abrasion, catastrophic failure due to diffusion, chipping and notch wear are noticed as the major tool wear mechanisms in hard turning. Mathematical machinability models show statistically significance because due to the superior coefficient of correlations. As the global machining cost for each part is less, uncoated carbide tools can machine effectively, efficiently and economically at optimum cutting conditions under spray environment.

An Analysis of Tool Life Based on Flank-Face Wear—Part 2: Comparison of Theory With Experimental Observations

1976 ◽  
Vol 98 (1) ◽  
pp. 227-232 ◽  
Author(s):  
C. Rubenstein
Keyword(s):  
Experimental Evidence ◽  
Tool Life ◽  
Flank Wear ◽  
Large Body ◽  
Cutting Conditions ◽  
Subsurface Layers ◽  
Flank Face

In Part 1 of this paper (Paper No. 75-WA/Prod-28) an analysis of tool life based on a flank-wear criterion was made based on the hypothesis that there exists a range of cutting conditions within which the temperature of the subsurface layers of the workpiece are virtually unaffected while the temperature of the subsurface layers of the tool rises considerably. In the present paper a large body of published experimental evidence is adduced and shown to be consistent with the results of the analysis and, thus, lends support to the hypothesis on which the analysis is based.

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