Wear Analysis of ZTA-MgO Ceramic Cutting Inserts on Stainless Steel 316L Machining

The performance of zirconia toughened alumina with addition of MgO additives is investigated. Optimized composition of MgO at 1.1 wt% was used in the composition with alumina/yittria stabilized zirconia (YSZ). The composition was mixed, uniaxially pressed into rhombic 80o cutting inserts with 0.8 mm nose radius and sintered at 1600oC for 4 h in pressureless condition. For machining analysis, commercial stainless steel 316L with 12 mm diameter were used as workpiece. The workpiece was machined at 625 to 1750 rpm. Tool wear and surface roughness of workpiece were measured. Result shows three types of wear behaviour appear which are flank wear, notch wear and chipping. Flank wear and notch wear increased with the cutting speed but decrease by increasing the feedrate before increased after passing the 0.2mm/rev feedrate. While chipping very much related to the feedrate as the chipping area increased when the feedrate increased. Meanwhile, surface roughness increase with increment of cutting speed and feedrate which match the wear pattern.

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Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.447-448.51 ◽

2010 ◽

Vol 447-448 ◽

pp. 51-54

Author(s):

Mohd Fazuri Abdullah ◽

Muhammad Ilman Hakimi Chua Abdullah ◽

Abu Bakar Sulong ◽

Jaharah A. Ghani

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Surface Finish ◽

Feed Rate ◽

Cutting Speed ◽

Chip Thickness ◽

Cutting Parameters ◽

Depth Of Cut ◽

Nose Radius ◽

Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

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The Cutting Speed Influences on Tool Wear of ZTA Ceramic Cutting Tools and Surface Roughness of Work Material Stainless Steel 316L during High Speed Machining

Materials Science Forum ◽

10.4028/www.scientific.net/msf.840.315 ◽

2016 ◽

Vol 840 ◽

pp. 315-320 ◽

Cited By ~ 1

Author(s):

Afifah Mohd Ali ◽

Norazharuddin Shah Abdullah ◽

Manimaran Ratnam ◽

Zainal Arifin Ahmad

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Tool Wear ◽

High Speed ◽

Dense Body ◽

Cutting Speed ◽

Optical Microscope ◽

Stainless Steel 316L ◽

Crater Wear ◽

Matlab Programming

The purpose of this research is to find the effects of cutting speed on the performance of the ZTA ceramic cutting tool. Three types of ZTA tools used in this study which are ZTA-MgO(micro), ZTA-MgO(nano) and ZTA-MgO-CeO2. Each of them were fabricated by wet mixing the materials, then dried at 100°C before crushed into powder. The powder was pressed into rhombic shape and sintered at 1600°C at 4 hours soaking time to yield dense body. To study the effect of the cutting speed on fabricated tool, machining was performed on the stainless steel 316L at 1500 to 2000 rpm cutting speed. Surface roughness of workpiece was measured and the tool wears were analysed by using optical microscope and Matlab programming where two types of wear measured i.e. nose wear and crater wear. Result shows that by increasing the cutting speed, the nose wear and crater wear increased due to high abrasion. However, surface roughness decreased due to temperature rise causing easier chip formation leaving a good quality surface although the tool wear is increased.

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Optimization of flank wear and surface roughness during turning of AISI 304 stainless steel using the Taguchi method

Materials Testing ◽

10.1515/mt-2020-620915 ◽

2020 ◽

Vol 62 (9) ◽

pp. 957-961

Author(s):

Nursel Altan Özbek ◽

Metin İbrahim Karadag ◽

Onur Özbek

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Taguchi Method ◽

Feed Rate ◽

Flank Wear ◽

Signal To Noise Ratio ◽

Cutting Speed ◽

304 Stainless Steel ◽

Aisi 304 Stainless Steel ◽

Aisi 304

Abstract This paper presents the effect of cutting tool, cutting speed and feed rate on the flank wear and surface roughness of austenitic stainless steel (AISI 304) during wet turning. Turning tests were designed based on the Taguchi method (L18). An orthogonal array, the signal-to-noise ratio (S/N) and the ANOVA were used to investigate the machinability of AISI 304 stainless steel with PVD and CVD coated tungsten carbide inserts. As a result of ANOVA, it was found that the feed rate was the most effective parameter on both flank wear and surface roughness.

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Post-Processing and Surface Characterization of Additively Manufactured Stainless Steel 316L Lattice: Implications for BioMedical Use

Materials ◽

10.3390/ma14061376 ◽

2021 ◽

Vol 14 (6) ◽

pp. 1376

Author(s):

Alex Quok An Teo ◽

Lina Yan ◽

Akshay Chaudhari ◽

Gavin Kane O’Neill

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Surface Characterization ◽

High Surface ◽

Surface Characteristics ◽

Post Processing ◽

Stainless Steel 316L ◽

Processing Methods ◽

Particulate Debris

Additive manufacturing of stainless steel is becoming increasingly accessible, allowing for the customisation of structure and surface characteristics; there is little guidance for the post-processing of these metals. We carried out this study to ascertain the effects of various combinations of post-processing methods on the surface of an additively manufactured stainless steel 316L lattice. We also characterized the nature of residual surface particles found after these processes via energy-dispersive X-ray spectroscopy. Finally, we measured the surface roughness of the post-processing lattices via digital microscopy. The native lattices had a predictably high surface roughness from partially molten particles. Sandblasting effectively removed this but damaged the surface, introducing a peel-off layer, as well as leaving surface residue from the glass beads used. The addition of either abrasive polishing or electropolishing removed the peel-off layer but introduced other surface deficiencies making it more susceptible to corrosion. Finally, when electropolishing was performed after the above processes, there was a significant reduction in residual surface particles. The constitution of the particulate debris as well as the lattice surface roughness following each post-processing method varied, with potential implications for clinical use. The work provides a good base for future development of post-processing methods for additively manufactured stainless steel.

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An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽

10.3390/mi12040460 ◽

2021 ◽

Vol 12 (4) ◽

pp. 460

Author(s):

Canbin Zhang ◽

Chifai Cheung ◽

Benjamin Bulla ◽

Chenyang Zhao

Keyword(s):

Surface Roughness ◽

Ultrasonic Vibration ◽

High Frequency ◽

Optical Glass ◽

Contact Point ◽

Cutting Speed ◽

Optical Quality ◽

Machining Parameters ◽

Nose Radius ◽

Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

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Experimental Investigation on Surface Roughness in Precision Cutting Ti6Al4V Alloy Using Diamond Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.576 ◽

2014 ◽

Vol 800-801 ◽

pp. 576-579

Author(s):

Lin Hua Hu ◽

Ming Zhou ◽

Yu Liang Zhang

Keyword(s):

Surface Roughness ◽

Cutting Speed ◽

Polycrystalline Diamond ◽

Cutting Parameters ◽

Limited Range ◽

Nose Radius ◽

Machined Surface ◽

Machined Surface Roughness ◽

Titanium Alloy Ti6al4v ◽

Pcd Tools

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using polycrystalline diamond (PCD) tools to investigate the effects of the tool geometries and cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the flank angle, tool nose radius and cutting speed within a limited range respectively, and begins to increase as the factors reaches to certain values respectively. And machined surface roughness decreases with increases in feed rate and cutting depth respectively.

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OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

Surface Review and Letters ◽

10.1142/s0218625x22500299 ◽

2021 ◽

Author(s):

MAHIR AKGÜN

Keyword(s):

Surface Roughness ◽

Power Consumption ◽

Cutting Force ◽

Cutting Speed ◽

System Optimization ◽

Gray Relational Analysis ◽

Depth Of Cut ◽

Nose Radius ◽

Significance Level ◽

Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

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Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

MATEC Web of Conferences ◽

10.1051/matecconf/201814203002 ◽

2018 ◽

Vol 142 ◽

pp. 03002

Author(s):

Yunhai Jia ◽

Lixin Zhu

Keyword(s):

Surface Roughness ◽

Experimental Design ◽

Boron Nitride ◽

Feed Rate ◽

Flank Wear ◽

Cubic Boron Nitride ◽

Cutting Tools ◽

Cutting Speed ◽

Orthogonal Experimental Design ◽

Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

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An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

Journal of Micro and Nano-Manufacturing ◽

10.1115/1.4046560 ◽

2020 ◽

Vol 8 (2) ◽

Cited By ~ 1

Author(s):

Yunn-Shiuan Liao ◽

Tsung-Hsien Li ◽

Yi-Chen Liu

Keyword(s):

Carbon Dioxide ◽

Surface Roughness ◽

Titanium Alloy ◽

Flank Wear ◽

End Milling ◽

Cutting Speed ◽

Liquid Carbon ◽

Dry Cutting ◽

Machined Surface ◽

Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

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Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

Coatings ◽

10.3390/coatings10121259 ◽

2020 ◽

Vol 10 (12) ◽

pp. 1259

Author(s):

Emre Altas ◽

Hasan Gokkaya ◽

Meltem Altin Karatas ◽

Dervis Ozkan

Keyword(s):

Surface Roughness ◽

Shape Memory Alloy ◽

Shape Memory ◽

Flank Wear ◽

Cutting Tools ◽

Dominant Factor ◽

Niti Shape Memory Alloy ◽

Machining Parameters ◽

Nose Radius ◽

Dry Cutting

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

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