Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 894-900 ◽  
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari ◽  
Nurhayati Ab. Razak
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Room Temperature ◽  
End Milling ◽  
Hardened Steel ◽  
Cutting Conditions ◽  
Preheating Temperature ◽  
Aisi H13 ◽  
Coated Carbide

Hardened materials like AISI H13 steel are generally regarded as s difficult to cut materials because of their hardness due to intense of carbon content, which however allows them to be used extensively in the hot working tools, dies and moulds. The challenges in machining steels at their hardened state led the way to many research works in amelioration its machinability. In this paper, preheating technique has been used to improve the machinability of H13 hardened steel for different cutting conditions. An experimental study has been performed to assess the effect of workpiece preheating using induction heating system to enhance the machinability of AISI H13. The preheated machining of AISI H13 for two different cutting conditions with TiAlN coated carbide tool is evaluated by examining tool wear, surface roughness and vibration. The advantages of preheated machining are demonstrated by a much extended tool life and stable cut as lower vibration/chatter amplitudes. The effects of preheating temperature were also investigated on the chip morphology during the end milling of AISI H13 tool steel, which resulted in reduction of chip serration frequency. The preheating temperature was maintained below the phase change temperature of AISI H13. The experimental results show that preheated machining led to appreciable increasing tool life compared to room temperature machining. Abrasive wear, attrition wear and diffusion wear are found to be a very prominent mechanism of tool wear. It has been also observed that preheated machining of the material lead to better surface roughness values as compared to room temperature machining.

Investigation of Tool Wear, Tool Life and Surface Roughness when Machining AISI D2 Hardened Steel Using PVD TiAlN Coated Carbide Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1098-1102 ◽  
Author(s):  
Noor Hakim Rafai ◽  
Mohd Amri Lajis ◽  
N.A.J. Hosni
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Material Removal ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Tool Failure ◽  
Aisi D2 ◽  
Wear Tool ◽  
Coated Carbide

This paper discussed the behavior of cutting tool in terms of tool wear, tool life and surface roughness when machining an AISI D2 hardened steel. An experimental test was conducted at different cutting speeds (Vc) and radial depth of cut (ae) using PVD TiAlN coated carbide tool under dry condition. Tool failure modes and tool wear mechanism for all cutting tools were examined at various cutting parameters. Flank wear was found to be the predominant tool failure for cutting tools. The highest volume material removal (VMR) attained was 3750 mm3 meanwhile the highest tool life (TL) was 9.69 min. The surface roughness (Ra) values from 0.09 to 0.24 μm can be attained in the workpiece with a high material removal. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high material removal, maximum tool life as well as acceptable surface finish.

Performance Evaluation of PCBN in End Milling of AISI D2 Hardened Steel under Room and Preheated Machining Conditions

2011 ◽  
Vol 264-265 ◽  
pp. 901-906 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
Turnad L. Ginta
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
End Milling ◽  
High Stress ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Wear Performance ◽  
Machining Conditions ◽  
Preheating Temperature ◽  
Aisi D2

In this paper, the tool life and tool wear performance of PCBN tool in end milling of AISI D2 hardened steel under room and preheated machining conditions is presented. The tool life and tool wear patterns were examined through tool maker microscope and scanning electron microscope. The results show that the dominant modes of tool wear observed were flank wear, chipping, and notch wear. The main wear mechanisms were abrasion, adhesion, and diffusion promoted by high stress and cutting temperature. It was also observed that longer tool life and higher volume metal removed could be achieved when employing higher preheating temperature.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

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.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

Investigation of the Machinability of Inconel 718 in Room Temperature and Preheated Conditions

2011 ◽  
Vol 264-265 ◽  
pp. 1187-1192
Author(s):  
A.K.M. Nurul Amin ◽  
A. Fakhruzi Majed ◽  
M.K. Daud ◽  
Anayet Ullah Patwari ◽  
M.H. Ishtiyaq
Keyword(s):  
Inconel 718 ◽  
Room Temperature ◽  
End Milling ◽  
Chip Morphology ◽  
Material Surface ◽  
Work Piece ◽  
Aerospace Materials ◽  
Space Navigation ◽  
Preheating Temperature ◽  
Coated Carbide

Inconel 718 is widely used in the aviation, space, navigation and shipping industries because of its outstanding properties. The very mechanical characteristics that give this alloy the highly valued properties also make it one of the most difficult-to-machine aerospace materials. Due to the hardness of nickel-based super-alloys, such as Inconel 718, advanced tools like ceramics have been recommended to machine them. But ceramics are low conductive materials, and the heat generated during the machining of Inconel 718 transfers very slowly through them. The accumulation of generated heat on the cutting edges of ceramic tools causes many problems and sometime leads to premature tool failure. Hence in this study the effectiveness of PVD TiAlN coated carbide insert has been investigated. One approach to overcome the difficulties in machining of Inconel 718 is to use an external heat source to soften the work material surface layer to be removed in order to decrease its tensile strength. A new approach of preheating using inducting heating as an economical alternative to Laser Assisted Machining for end milling of Inconel 718 is presented in this paper. The machinability of Inconel 718 under varying conditions is evaluated by examining tool wear, surface roughness and chip morphology. With increasing work-piece preheating temperature, from room temperature to 420 °C, the advantages of Induction heating is demonstrated by an extended tool life and better surface finish due to more stable chip formation and elimination of micro and macro failure of the tool.

Influence of Cutter’s Helix Angle, Workpiece Hardness, Milling Orientation, and MQL in High-Speed Side Milling of AISI D2

2006 ◽  
Vol 532-533 ◽  
pp. 45-48 ◽  
Author(s):  
Asif Iqbal ◽  
Ning He ◽  
Liang Li ◽  
Yu Xia
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Helix Angle ◽  
Workpiece Material ◽  
Side Milling ◽  
Material Hardness ◽  
Aisi D2 ◽  
Coated Carbide

Rapid tool wear is a major demerit of high-speed milling (HSM) applied to cutting of hardened steels, especially the AISI D2. This paper presents an attempt to maximize the tool life by experimentally investigating the effects of cutter’s helix angle, workpiece material hardness, milling orientation, and minimum quantity of lubrication upon tool wear in high-speed side milling of AISI D2, using coated carbide cutters. Effects of these four parameters were studied also upon surface roughness. Statistical analysis upon experimental data revealed that milling orientation was the most significant factor for tool life as well as for surface roughness. The paper also describes the mechanisms of wear undergone by the tools, by making use of SEM photographs and EDS microanalysis. The major wear mechanisms were chipping, adhesion, and diffusion.

Effect of Tool Wear on Tri-Phase CVD Coated Carbide Tools Life while Turning Al6061

2012 ◽  
Vol 488-489 ◽  
pp. 457-461 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Abdolkarim Niazi
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Orthogonal Cutting ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Tool Edge ◽  
Product Surface ◽  
Coated Carbide

Aluminum 6061 is a common alloy which is widely used in aerospace and yacht construction industry. Generally machining of aluminum alloys inherently generates high chip sticking on tool face and changes the tool edge geometry, which not only reduces tool life but also impairs the product surface quality. This study investigated the tool life and tool wear mechanisms besides evaluating surface roughness in various cutting conditions to attain finest possible surface with minimum tool wear. Turning experiments performed under dry orthogonal cutting of Al6061 using carbide CVD tri-phase coated inserts with constant depth of cut, various cutting speeds and feed rates. Insert’s flank and rake faces analyzed to assess wear mechanisms. Additionally Scanning electron microscope (SEM) employed to clarify different types of wear. Surface integrity and effect of built up edge in deviating surface roughness were studied in each cutting condition. Additionally results of experiments demonstrated that built up edge took over cutting edge and with sacrificing surface roughness, tool life increased by decreasing pace of abrasive wear propagation on flank face. According to these experiments the main reasons of flank wear were abrasive and adhesion of aluminum on tool face.

Preheating in End Milling of AISI D2 Hardened Steel with Coated Carbide Inserts

2009 ◽  
Vol 83-86 ◽  
pp. 56-66 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
A.M.K. Hafiz
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Inductive Heating ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Coated Carbide

This study was conducted to investigate the effect of preheating through inductive heating mechanism in end milling of AISI D2 hardened steel (60-62 HRC) by using coated carbide tool inserts. Apart from preheating, two other machining parameters such as cutting speed and feed were varied while the depth of cut constant was kept constant. Tool wear phenomenon and machined surface finish were found to be significantly affected by preheating temperature and other two variables. End milling operation was performed on a Vertical Machining Centre (VMC). Preheating of the work material to a higher temperature range resulted in a noticeable reduction in tool wear rate leading to a longer tool life. In addition, improved surface finish was obtained with surface roughness values lower than 0.4 μm, leaving a possibility of skipping the grinding and polishing operations for certain applications.

Tool Wear Performance of TiAlN/AlCrN Multilayer Coated Carbide Tool in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 462-467
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis ◽  
K. Kamdani
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Tools ◽  
High Volume ◽  
Hardened Steel ◽  
Wear Performance ◽  
Tool Failure ◽  
Aisi D2 ◽  
Coated Carbide

This paper presents the results of experimental investigation conducted on a vertical machining centre (VMC) to ascertain the effectiveness of TiAlN/AlCrN multilayer coated carbide inserts in end milling of AISI D2 hardened steel (58-62 HRC) In high-speed dry hard milling, different cutting speed (v) and radial depth of cut (dr) were applied. Tool failure modes and wear mechanisms were examined at various cutting parameters. Flank wear, chipping and breakage at cutting edge were found to be the predominant tool failure for the cutting tools. Built-up edge, adhesion and abrasive are the wear mechanisms observed on the cutting tools. The highest volume of material removed, VMR attained was 1500 mm3, meanwhile the highest tool life (T) was 4.97 min. The surface roughness, Ra values from 0.20 to 0.45 μm can be attained in the workpiece with a high volume material removed. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high volume material removed, maximum tool life as well as acceptable surface finish.

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