Identification, Analysis and Evolution of the Mechanisms of Wear for Secondary Adhesion for Dry Turning Processes of Al-Cu Alloys

2010 ◽  
Vol 107 ◽  
pp. 141-146 ◽  
Author(s):  
Moisés Batista ◽  
J. Salguero ◽  
Alvaro Gómez ◽  
M.S. Carrilero ◽  
Miguel Álvarez ◽  
...  
Keyword(s):  
Tool Wear ◽  
Critical Size ◽  
Main Tool ◽  
Machining Process ◽  
Rake Face ◽  
Turning Process ◽  
Dry Turning ◽  
Cu Alloys ◽  
Tool Wear Mechanism ◽  
Identification Analysis

In this work, Stereoscopic Optical Microscopy (SOM), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) have been applied for analyzing the evolution of tool wear during the dry turning process of aerospace Al-Cu alloys. The results derived from this analysis have revealed that secondary adhesion is the main tool wear mechanism that takes place in such process. So, in the first instants of the machining process, a Built-Up Layer (BUL) is developed onto the tool rake face by thermomechanical causes, promoting the conditions for developing a Built-Up Edge (BUE) which grows to a critical size. Starting from it, BUE is extruded giving rise to secondary BUL-BUE effects. When these are removed, tool particles are dragged out provoking the tool wear.

scholarly journals Influence of Tool Wear on Form Deviations in Dry Machining of UNS A97075 Alloy

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 958
Author(s):  
Francisco Javier Trujillo Vilches ◽  
Sergio Martín Béjar ◽  
Carolina Bermudo Gamboa ◽  
Manuel Herrera Fernández ◽  
Lorenzo Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
General Trend ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Adhesion Wear ◽  
Tool Wear Mechanisms ◽  
Tool Wear Mechanism ◽  
High Feed ◽  
Dry Conditions

Geometrical tolerances play a very important role in the functionality and assembly of parts made of light alloys for aeronautical applications. These parts are frequently machined in dry conditions. Under these conditions, the tool wear becomes one of the most important variables that influence geometrical tolerances. In this work, the influence of tool wear on roundness, straightness and cylindricity of dry-turned UNS A97075 alloy has been analyzed. The tool wear and form deviations evolution as a function of the cutting parameters and the cutting time has been assessed. In addition, the predominant tool wear mechanisms have been checked. The experimental results revealed that the indirect adhesion wear (BUL and BUE) was the main tool-wear mechanism, with the feed being the most influential cutting parameter. The combination of high feed and low cutting speed values resulted in the highest tool wear. The analyzed form deviations showed a general trend to increase with both cutting parameters. The tool wear and the form deviations tend to increase with the cutting time only within the intermediate range of feed tested. As the main novelty, a relationship between the cutting parameters, the cutting time (and, indirectly, the tool wear) and the analyzed form deviations has been found.

Control Method for Elimination of Self–Excited Oscillations during Turning

2010 ◽  
Vol 164 ◽  
pp. 171-176 ◽  
Author(s):  
Tomáš Březina ◽  
Jan Vetiška ◽  
Petr Blecha ◽  
Pavel Houška
Keyword(s):  
Tool Wear ◽  
Computer Model ◽  
Pid Controller ◽  
Control Method ◽  
The Self ◽  
Machining Process ◽  
Geometric Accuracy ◽  
Turning Process ◽  
Machined Surface ◽  
Excited Oscillation

The oscillations occurring between the tool and the machined area during the turning process lead to degradation of the machined surface, cause poor geometric accuracy, accelerate tool wear and generate noise. This paper deals with the possibility of elimination of these self-excited oscillations by changing the parameters of the turning process. On the basis of the regenerative principle of self-excited oscillation generation, a computer model of the machining process was developed. Furthermore, a PID controller was proposed to control the compensation of the vibrations and its suitability for elimination of the self-excited oscillations was verified experimentally.

Analysis of secondary adhesion tool wear effects on surface roughness in dry turning process of UNS A92024 aluminium alloy

2017 ◽  
Vol 10 (1) ◽  
pp. 23
Author(s):  
Daniel Garcia Jurado ◽  
Juan Manuel Vázquez Martínez ◽  
Antonio J. Gámez ◽  
M. Batista ◽  
F.J. Puerta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Aluminium Alloy ◽  
Turning Process ◽  
Dry Turning

Analysis of secondary adhesion tool wear effects on surface roughness in dry turning process of UNS A92024 aluminium alloy

2017 ◽  
Vol 10 (1) ◽  
pp. 23
Author(s):  
M. Marcos ◽  
F.J. Puerta ◽  
M. Batista ◽  
Antonio J. Gámez ◽  
Daniel Garcia Jurado ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Aluminium Alloy ◽  
Turning Process ◽  
Dry Turning

Cutting Tool Crater Wear Measurement in Turning Using Chip Geometry and Genetic Programming

2015 ◽  
Vol 6 (1) ◽  
pp. 47-60 ◽  
Author(s):  
Mohammad Zadshakoyan ◽  
Vahid Pourmostaghimi
Keyword(s):  
Tool Wear ◽  
Cutting Speed ◽  
Machining Process ◽  
Turning Process ◽  
Effective Parameters ◽  
Crater Wear ◽  
Geometrical Features ◽  
Tool Wear Estimation ◽  
Industry Automation ◽  
And Control

Tool wear prediction plays an important role in industry automation for higher productivity and acceptable product quality. Therefore, in order to increase the productivity of turning process, various researches have been made recently for tool wear estimation and classification in turning process. Chip form is one of the most important factors commonly considered in evaluating the performance of machining process. On account of the effect of the progressive tool wear on the shape and geometrical features of produced chip, it is possible to predict some measurable machining outputs such as crater wear. According to experimentally performed researches, cutting speed and cutting time are two extremely effective parameters which contribute to the development of the crater wear on the tool rake face. As a result, these parameters will change the chip radius and geometry. This paper presents the development of the genetic equation for the tool wear using occurred changes in chip radius in turning process. The development of the equation combines different methods and technologies like evolutionary methods, manufacturing technology, measuring and control technology with the adequate hardware and software support. The results obtained from genetic equation and experiments showed that obtained genetic equations are correlated well with the experimental data. Furthermore, it can be used for tool wear estimation during cutting process and because of its parametric form, genetic equation enables us to analyze the effect of input parameters on the crater wear parameters.

Study on the Wear of Cutting-Tools Used in Dry Machining of Cu-10wt%Al-5wt%Ni-5wt%Fe Alloy

2021 ◽  
Vol 413 ◽  
pp. 194-200
Author(s):  
Marcos de Aguiar Guimarães ◽  
Givanildo Alves dos Santos ◽  
Mauricio S. Nascimento ◽  
Rogerio Teram ◽  
Vinicius Torres dos Santos ◽  
...  
Keyword(s):  
Tool Wear ◽  
Copper Alloys ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Lower Surface ◽  
Raw Material ◽  
Machining Process ◽  
Dry Machining ◽  
Aluminium Bronze

Aluminium bronze alloys are special copper alloys that have a machinability rate from 20 to 40% compared to free cutting brasses, so the cutting parameters and type of tools suitable for machining of these materials may be very different for other copper alloys. Also, due to the relative high costs of the raw material, the absence of contamination of the chips by cutting fluids improve its intrinsic resales value and encourage the use of machining process without coolant. The aim of this work is to evaluate the tool wear mechanisms in the finishing machining of the Cu-10wt%Al-5wt%Ni-5wt%Fe aluminium-bronze alloy with carbide and cermet inserts at different cutting speeds under dry machining condition. The turning of material showed lower surface roughness in higher speed conditions and better dimensional stability at lower speeds. It was observed the formation of continuous chips, but of little volume occupied. The scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) analyses of tool wear show the adhesion as the main tool wear mechanism, followed by abrasion. At the lower cutting speed, the adhesion wears affected significantly the surface finish, reducing the tool life in comparison to the higher speeds.

Effect of High Pressure Coolant on Tool Wear Phenomenon during Machining of Titanium Alloy Ti6Al4V

2016 ◽  
Vol 826 ◽  
pp. 93-98 ◽  
Author(s):  
Pravin Pawar ◽  
Sandip Patil ◽  
Swapnil Kekade ◽  
Swapnil Pawar ◽  
Rajkumar Singh
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Chemical Reactivity ◽  
Cutting Temperature ◽  
Machining Process ◽  
Tool Wear Mechanism ◽  
Flank Face ◽  
Titanium Alloy Ti6al4v ◽  
High Pressure Coolant

Titanium alloys are referred to difficult-to-cut materials because of its some inferior properties like low thermal conductivity and high chemical reactivity. To improve machinability of these alloys one way is to use cutting fluids which removes the heat generated at the chip tool interface during the machining process. But coolant with low pressure and improper delivery is not able to break the vapor barrier created by high cutting temperature. The present work investigates the effect of using high pressure coolant system (50 Bar) on machinability of Ti6Al4V. The machinability was measured in terms of tool wear. The dominant tool wear mechanism was investigated by using scanning electron microscopy and energy dispersive X-ray analysis of worn out cutting tool surfaces. Abrasion wear on flank face and crater wear on the rake face was observed as a dominant tool wear mechanism. Along with this diffusion of titanium from the work surface to tool face is also confirmed.

A Comparative Study of I-kaz Based Signal Analysis Techniques: Application to Detect Tool Wear during Turning Process

2013 ◽  
Vol 66 (3) ◽  
Author(s):  
Muhammad Rizal ◽  
Jaharah A. Ghani ◽  
Mohd Zaki Nuawi ◽  
Mohamad Amir Shafiq r Mohd Tahir ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Multilevel Methods ◽  
Machining Process ◽  
Turning Process ◽  
Feed Force ◽  
Machined Parts ◽  
Force Signal ◽  
Analysis Of Results

Detection of tool wear during in-progress machining process is a significant requirement to assure the quality of machined parts that helps to improve the productivity. The cutting force is one of the signals in machining process that has been widely used for tool wear monitoring. In the present paper three derived I-kazTM based methods explained and compared for monitoring tool wear changes during turning process. The aim of this work is to study the performance of I-kazTM, I-kaz 2D and I-kaz Multilevel techniques to detect flank wear width using the cutting force signal. The experiments were carried out by turning hardened carbon steel, and cutting force signals were measured by two channels of strain gauges that were mounted on the surface of tool holder. The analysis of results using I-kaz 2D, I-kazTM and also I-kaz Multilevel methods, revealed that all methods can applied to determine tool wear progression during turning process and feed force signal change is very significant due to flank wear.

Research on Chemical Transformation of Diamond with Fe Catalysis Based on Thermal Analysis

2012 ◽  
Vol 723 ◽  
pp. 105-109
Author(s):  
Lai Zou ◽  
Guo Jun Dong ◽  
Ming Zhou
Keyword(s):  
Thermal Analysis ◽  
Tool Wear ◽  
Chemical Transformation ◽  
Machining Process ◽  
Surface Wear ◽  
Analysis Method ◽  
Ferrous Metals ◽  
Single Crystal Diamond ◽  
Tool Wear Mechanism ◽  
And Diffusion

It is known that diamond is not suitable for cutting of ferrous metals, ascribed to serious tool wear occurred in machining process. For the sake of studying the tool wear mechanism further, this paper presents thermal analysis method to discuss the chemical transformation of diamond with Fe catalysis. Raman scattering experiment was performed to identify the transformation of crystal structure of the diamond specimens. The surface wear morphology of workpiece was detected by scanning electron microscopy, and energy dispersive X-ray analysis was used to study the change of chemical composition. Experimental results revealed the law of graphitization and diffusion of single crystal diamond at elevated temperature in different gas environment.

Sign in / Sign up

Export Citation Format

Share Document