Performance of CBN and PCBN Tools on the Machining of Hard AISI 440C Martensitic Stainless Steel

2011 ◽  
Vol 264-265 ◽  
pp. 1137-1147 ◽  
Author(s):  
S. Thamizhmanii ◽  
Rosli Ahmad ◽  
S. Hasan
Keyword(s):  
Stainless Steel ◽  
Cutting Forces ◽  
Flank Wear ◽  
Martensitic Stainless Steel ◽  
Dimensional Accuracy ◽  
Hard Metal ◽  
Depth Of Cut ◽  
Tool Surface ◽  
Pcbn Tools ◽  
Cutting Speeds

In this study, flank wear on CBN and PCBN tools due to cutting forces were studied. Turning tests were carried using cutting speeds of 100, 125, 150, 175 and 200 m/min with feed rates of 0.10, 0.20 and 0.30 mm/rev and constant depth of cut. The performances of tools were evaluated based on the flank wear and cutting forces. There is clear relationship between flank wear and cutting forces while turning hard martensitic stainless steel by CBN and PCBN tools. Low cutting forces leads to low flank wear formation and low cutting forces provided good dimensional accuracy of the work material including low surface roughness. Flank wear formation was mostly caused by abrasion and adhesion. The built up edges formed reduced the cutting forces and also causes the heat generated at tool tip and work interface. High cutting forces are identified and this may be due to heat and flank wear combinations. Flank and crater wear on the rake face and hard metal deposition due to diffusion of metals on the cutting tool surface are the damages occurred during process.

scholarly journals Impact of Cutting Speed on Tool Life of Coated and Uncoated Cemented Carbide during Turning of S31700 Grade Stainless Steel

2020 ◽  
Vol 9 (5) ◽  
pp. 2022-2025
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Stainless Steels ◽  
Entire Range ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cemented Carbides ◽  
Depth Of Cut ◽  
Cutting Speeds

Here, we found and observed different results of experimental work in dry turning of S31700 grade stainless steels using coated and uncoated cemented carbides. The turning tests were conducted at three different cutting speeds (150and 200m/min) while feed rate and depth of cut were kept constant at 0.3 mm/rev and 1 mm, respectively. The cutting tools used were ISO P30 uncoated and TiN-TiCN-Al2O3 -ZrCN coated cemented carbides. We found the influences of cutting speed on the average flank wear. The worn parts of the cutting tools were also examined using optical microscopy and SEM. Here we concluded that cutting speed significantly affected the average flank wear. The multilayer effects superior resistance to tool wear compared to its uncoated counterpart in the entire range of cutting speeds during turning of S31700 stainless (AISI317) steel.

On the Wear Mechanisms and Cutting Performance of Silicon Carbide Whisker-Reinforced Alumina

1992 ◽  
Vol 114 (3) ◽  
pp. 301-308 ◽  
Author(s):  
A. R. Thangaraj ◽  
K. J. Weinmann
Keyword(s):  
Silicon Carbide ◽  
Wear Mechanisms ◽  
Flank Wear ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Tool Failure ◽  
Silicon Carbide Whisker ◽  
Nickel Based Superalloy ◽  
Notch Wear ◽  
Cutting Speeds

The objective of this research was to study the types of wear suffered by silicon carbide whisker-reinforced aluminum oxide inserts in the machining of Inconel 718. Further, it was desired to study the effects of tool wear and cutting conditions on cutting forces, workpiece dimensional accuracy, and surface finish. Machining tests were conducted using 12.7 mm diameter round inserts at cutting speeds ranging from 6.0 to 13.0 m/s. The feed rates ranged from 0.13 to 0.51 mm/rev and two depths of cut of 0.76 and 1.27 mm were used. Tool failure in the cutting of the relatively soft (220 HB) nickel-based superalloy was due to excessive wear. Flank wear played a larger role at the lower speeds, but depth-of-cut notch wear was significant at the higher speeds. Abrasion, adhesion, and chipping were found to be the dominant wear mechanisms. The results of this study are presented and discussed in this paper.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Cutting Forces and Vibration of Pockets Corner by High Speed Milling

2009 ◽  
Vol 69-70 ◽  
pp. 59-63 ◽  
Author(s):  
Cheng Yong Wang ◽  
De Weng Tang ◽  
Zhe Qin ◽  
Z.G. Chen ◽  
Ying Ning Hu ◽  
...  
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Sudden Change ◽  
Poor Quality ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Cutting Direction ◽  
Cutting Speeds

When the pocket in die and mould is machined by high speed milling (HSM), the cutting forces increase and vibration fluctuates at the pocket corner because of the sudden change of cutting direction in general. It will cause serious wear and possible breakage of cutting tool, and poor quality of parts. By means of experiments, the cutting forces and vibration at the pocket corner with different HSM conditions are measured. The results show that the sharper pocket corner, higher cutting speeds, larger feed rate per tooth and radial depth of cut, will result in increasing of cutting forces and vibration amplitude. Thus, it will lead to be unstable during the process of high speed milling pocket corner.

Comparative experimental research in turning of 304 austenitic stainless steel with and without ultrasonic vibration

2016 ◽  
Vol 231 (15) ◽  
pp. 2885-2901 ◽  
Author(s):  
Yingshuai Xu ◽  
Ping Zou ◽  
Yu He ◽  
Shuo Chen ◽  
Yingjian Tian ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Wear ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
304 Austenitic Stainless Steel ◽  
Machining System

The aim of this paper is to present an experimental investigation of the cutting forces, surface quality, tool wear and chip shape in ultrasonic vibration assisted turning (UAT) of 304 austenitic stainless steel (ASS 304) in comparison to conventional turning (CT). This study focuses on the solution of the machining difficulties of ASS 304 and high demands for the processing quality and efficiency. The machining system of UAT is schemed out to assure the desired machining effect by utilizing ultrasonic vibration method. Meanwhile, a series of systematic experiments are performed with and without ultrasonic vibration using the designed machining system of UAT with cemented carbide coated cutting tool. The results obtained from the UAT and CT experiments demonstrate that the cutting effect of UAT is much better than that of CT. Furthermore, the results of this research indicate that the ultrasonic amplitude, cutting speed, feed rate and depth of cut in UAT of ASS 304 have visible influence on the cutting forces, surface quality and tool wear. And reasonable selection of various technological variables in UAT can obtain lower cutting forces, more superior surface roughness, advantageous surface topography, slow and less tool wear, thin and smooth chips.

scholarly journals An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4427
Author(s):  
Antoni Świć ◽  
Arkadiusz Gola ◽  
Olga Orynycz ◽  
Karol Tucki
Keyword(s):  
Control System ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Contact Heating ◽  
Thin Walled ◽  
Micro Machine

Low-rigidity thin-walled parts are components of many machines and devices, including high precision electric micro-machines used in control and tracking systems. Unfortunately, traditional machining methods used for machining such types of parts cause a significant reduction in efficiency and in many cases do not allow obtaining the required accuracy parameters. Moreover, they also fail to meet modern automation requirements and are uneconomical and inefficient. Therefore, the aim of provided studies was to investigate the dependency of cutting forces on cutting parameters and flank wear, as well as changes in cutting forces induced by changes in heating current density and machining parameters during the turning of thin-walled parts. The tests were carried out on a specially designed and constructed turning test stand for measuring cutting forces and temperature at specific cutting speed, feed rate, and depth of cut values. As part of the experiments, the effect of cutting parameters and flank wear on cutting forces, and the effect of heating current density and turning parameters on changes in cutting forces were analyzed. Moreover, the effect of cutting parameters (depth of cut, feed rate, and cutting speed) on temperature has been determined. Additionally, a system for controlling electro-contact heating and investigated the relationship between changes in cutting forces and machining time in the operations of turning micro-machine casings with and without the use of the control system was developed. The obtained results show that the application of an electro-contact heating control system allows to machine conical parts and semi-finished products at lower cutting forces and it leads to an increase in the deformation of the thin-walled casings caused by runout of the workpiece.

Force Modeling in Laser-Assisted Microgrooving Including the Effect of Machine Deflection

2009 ◽  
Vol 131 (1) ◽  
Author(s):  
Ramesh Singh ◽  
Shreyes N. Melkote
Keyword(s):  
Flow Stress ◽  
Cutting Force ◽  
Cutting Forces ◽  
Laser Power ◽  
Continuous Wave ◽  
Dimensional Accuracy ◽  
Thermal Softening ◽  
Depth Of Cut ◽  
Force Model ◽  
Cutting Force Model

Laser assisted mechanical micromachining is a process that utilizes highly localized thermal softening of the material by continuous wave laser irradiation applied simultaneously and directly in front of a miniature cutting tool in order to produce micron scale three-dimensional features in difficult-to-machine materials. The hybrid process is characterized by lower cutting forces and deflections, fewer tool failures, and potentially higher material removal rates. The desktop-sized machine used to implement this process has a finite stiffness and deflects under the influence of the cutting forces. The deflections can be of the same order of magnitude as the depth of cut in some cases, thereby having a negative effect on the dimensional accuracy of the micromachined feature. As a result, selection of the laser and cutting parameters that yield the desired reduction in cutting forces and deflection, and consequently an improvement in dimensional accuracy, requires a reliable cutting force model. This paper describes a cutting force model for the laser-assisted microgrooving process. The model accounts for the effect of elastic deflection of the machine X-Y stages on the forces and accuracy of the micromachined feature. The model combines an existing slip-line field based force model with a finite element based thermal model of laser heating and a constitutive material flow stress model to account for thermal softening. Experiments are carried out on H-13 steel (42 HRC (hardness measured on the Rockwell ‘C’ scale)) to validate the force model. The effects of process parameters, such as laser power and cutting speed, on the forces are also analyzed. The model captures the effect of thermal softening and indicates a 66% reduction in the shear flow stress at 35 W laser power. The cutting force and depth of cut prediction errors are less than 20% and 10%, respectively, for most of the cases examined.

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.

Magnetic Damping in Turning of Stainless Steel AISI 304 for the Reduction of Machining Vibration and Tool Wear

2015 ◽  
Vol 1115 ◽  
pp. 100-103
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Siti Aminatuzzuhriyah B. Haji Subir ◽  
Fawaz Mohsen Abdullah
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Aisi 304 ◽  
Excited Vibration ◽  
Coated Carbide

Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.

Wear Rate of CBN Cutting Tool in Hard Turning of 100Cr6 Bearing Steel

2013 ◽  
Vol 581 ◽  
pp. 50-54
Author(s):  
László Ráczkövi
Keyword(s):  
Wear Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Significant Proportion ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Average Wear ◽  
Cutting Speeds

The examination of wear and tool life of CBN cutting tools which are used for hard turning is a emphasized research theme, since the significant proportion of cost of machining associated with cutting tool. In this article we examined the wear of low CBN content cutting tool in case of hard turning of 100Cr6 bearing steel (HRC=62±2). The experiments were carried out with constant depth of cut and feed rate at three different cutting speeds. The flank wear of CBN inserts were measured after predetermined number of passes. The measured flank wear values were described as a function of cutting time and the calculated wear rate as a function of flank wear.The average wear rate were shown at three different cutting speeds.

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