Tool Life in High Speed Turning with Negative Rake Angle

2011 ◽  
Vol 264-265 ◽  
pp. 1009-1014 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz H.F. Al Hazza
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
High Speed Cutting ◽  
Life Estimation ◽  
High Speed Turning

The present work studies some aspects of turning process applied on mild steel using cermets tools at high speed cutting (1000mm/min) by using negative rake angle (0 to-12). The influence of increasing the cutting speed and negative rake angle on flank tool wear, cutting forces, feeding forces and tool temperature were analyzed. The research studies and concentrates on the tool life estimation and the effect of the negative rake angle and higher cutting speed on tool life. It was found that the maximum tool life is obtained in (-6) rake angle for the cutting parameters.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Experimental Study of Serrated Chip in High Speed Cutting

2012 ◽  
Vol 723 ◽  
pp. 99-104
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Shear Band ◽  
High Speed ◽  
Adiabatic Shear Band ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Adiabatic Shear ◽  
Cutting Depth ◽  
Serrated Chip ◽  
High Speed Cutting

In this paper, some high speed cutting experiments of hardened 45 steel are carried out. The effects of cutting parameters on the width and space of adiabatic shear band, the frequency and degree of sawtooth are investigated by metallographic observation and theoretical calculation. The results show that the space of adiabatic shear band decreases with the increase of cutting speed and rake angle, but increases with the increase of cutting depth. The width of adiabatic shear band decreases with the increase of cutting speed and cutting depth, however, increases with the increase of rake angle. The frequency of sawtooth increases with the increases of cutting speed, decreases with the increase of rake angle, and has no obvious relationship with cutting depth. The degree of sawtooth increases with the increase of cutting speed and cutting depth, but decreases with the increase of rake angle.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

scholarly journals Prediction of Tool Lifetime and Surface Roughness for Nickel-Based Waspaloy

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Shao-Hsien Chen ◽  
Chung-An Yu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Predictive Values ◽  
Actual Surface ◽  
Wide Range

In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Tool Wear Mechanisms in High Speed Machining Ductile Cast Iron

2010 ◽  
Vol 29-32 ◽  
pp. 1527-1531
Author(s):  
Fa Zhan Yang ◽  
Jian Qiang Zhou ◽  
Guang Yao Meng ◽  
Jun Zhao ◽  
Chang He Li
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Wear Behavior ◽  
Orthogonal Cutting ◽  
Ductile Cast Iron ◽  
Cemented Carbide ◽  
Rake Face ◽  
High Speed Cutting

Wear behavior of WC based nanocomposite cutting tool when high speed cutting ductile cast iron was investigated. Orthogonal cutting tests were carried out on a CA6140 lathe using three speeds, namely, 100, 215 and 287m min-1. The WC based nanocomposite tool is found to be superior to cemented carbide tools (YG8). The tool life is prolonged 60% as compared to cemented carbide, as the width of the wear land (VB), which was monitored at selected time intervals. Meanwhile, the topography of worn surfaces was scanned by a profilemeter. Wear characterization of the rake face and the flank surfaces as well as of the collected chips was conducted using a scanning electron microscopy (SEM). Results showed that distinctive traces of single abrasive tool wear event were found on the rake face of the tool, additionally, the adhesion wear is the main wear mechanism in the flank face of the tool. However, the extent of improvement in tool life depends strongly on the cutting conditions, with the greatest benefits being seen at higher cutting speeds and feed rates.

Experiment Study of Serrated Chip and Surface Roughness of High Speed Cutting of Ti6Al4V

2014 ◽  
Vol 800-801 ◽  
pp. 571-575
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hou Jun Qi
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Cutting Speed ◽  
Rake Angle ◽  
Adiabatic Shear ◽  
Cutting Condition ◽  
Experiment Study ◽  
Cutting Depth ◽  
Serrated Chip ◽  
High Speed Cutting

Under the condition of cutting speed 10-300m/min, rake angle -10°、0°、10°and cutting depths 0.05mm、0.1mm and 0.2mm, the experiment study of adiabatic shear serrated chip and surface roughness are carried out. The influence of cutting condition on serrated chip is analyzed through the metallographic observation of obtained chip. By the measurement of finished surface, the influenc of cutting condition and adiabatic shear on surface roughness is also investigated. The rusults show that the reason lead to serrated chip in high speed cutting of Ti6Al4V is adiabatic shear, not the periodic fracture.The adiabatic shear serrated chip is easier appear and the degree of segment is more large under the condition of higher cutting speed, larger cutting depth and smaller rake angle. The surface roughness is smaller when the cutting speed is higher, cutting depth is larger, and rake angle is smaller.

A Study of Relation between Roundness and Cutting Force in CNC Turning Process

2015 ◽  
Vol 799-800 ◽  
pp. 366-371 ◽  
Author(s):  
Deuanphan Chanthana ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Turning Process ◽  
Nose Radius ◽  
Cnc Turning ◽  
Cnc Turning Process ◽  
Tool Nose Radius

The roundness is one of the most important criteria to accept the mechanical parts in the CNC turning process. The relations of the roundness, the cutting conditions and the cutting forces in CNC turning is hence studied in this research. The dynamometer is installed on the turret of the CNC turning machine to measure the in-process cutting force signals. The cutting parameters are investigated to analyze the effects of them on the roundness which are the cutting speed, the feed rate, the depth of cut, the tool nose radius and the rake angle. The experimentally obtained results showed that the better roundness is obtained with an increase in cutting speed, tool nose radius and rake angle. The relation between the cutting parameters and the roundness can be explained by the in-process cutting forces. It is understood that the roundness can be monitored by using the in-process cutting forces.

Experimental Study on Tool Wear in Cutting Titanium Alloy Ti6Al4V

2011 ◽  
Vol 239-242 ◽  
pp. 2011-2014
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen ◽  
Wen Ying Zhang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Linear Regression Analysis ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Aged Condition ◽  
Cutting Depth ◽  
Solution Treated ◽  
Titanium Alloy Ti6al4v

Tool wear experiments in turning titanium alloy Ti6Al4V in the solution-treated and aged condition were carried out; the influence rules of cutting parameters such as cutting speed, feed rate and cutting depth on the tool life were obtained. Experimental formula of tool wear was regressed based on multi-variable linear regression analysis, it could predict tool life under certain conditions.

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