Study on Wear Properties and Mechanisms of Coated Carbide Tools in Dry Turning of 300M Steel

2011 ◽  
Vol 314-316 ◽  
pp. 1142-1145
Author(s):  
Zong Yang Zhang ◽  
Xing Ai ◽  
Zhan Qiang Liu ◽  
Min Wang
Keyword(s):  
Cutting Speed ◽  
No Oxidation ◽  
Depth Of Cut ◽  
Wear Properties ◽  
Workpiece Material ◽  
Dry Turning ◽  
300M Steel ◽  
Coated Carbide ◽  
Oxidation Wear ◽  
Coated Carbide Tools

This paper deals with an experimental research on wear properties and mechanisms of coated carbide tools in dry turning of 300M steel which are widely used to manufacture the central spindle, wheel gear, aerofoil fastener and so on. Based on Makarow’s theory, the minimum surface wear rate hs = 2.88 μm and the optimal cutting speed v = 200 m/mim were attained under the condition of the feed rate f = 0.1 mm/r and the depth of cut ap = 0.15 mm. Analysis carried out with the SEM suggests that adhesion of workpiece material and chipping are dominant wear mechanisms. There was no observation of oxygen existing based on the analysis of EDS which indicated no oxidation wear generated during the turning machining.

Wear Mechanisms of Coated Carbide Tools in Dry Boring of Titanium Alloys

2012 ◽  
Vol 499 ◽  
pp. 186-191
Author(s):  
Zong Yang Zhang ◽  
Zhan Qiang Liu ◽  
Xing Ai ◽  
B.L. Wang
Keyword(s):  
Titanium Alloys ◽  
Wear Mechanism ◽  
Feed Rate ◽  
Wear Mechanisms ◽  
Cutting Speed ◽  
No Oxidation ◽  
Depth Of Cut ◽  
Coated Carbide ◽  
Oxidation Wear ◽  
Coated Carbide Tools

This paper deals with an experimental research on the wear mechanism of coated carbide tools in dry boring of the titanium alloys TC11 which are commonly used for aero-engines. The wear mechanism of coated tool inserts was investigated at various combinations of cutting speed, feed rate, and depth of cut. Analysis carried out with the SEM suggests that adhesive wear and coating delamination are the dominant wear mechanisms under low speed and feed rate and depth of cut; while chipping and breakage are the dominant wear mechanisms for the combinations of high cutting speed, feed rate, and depth of cut. There was no observation of oxygen existing based on the analysis of SEM which indicated no oxidation wear generated during the boring machining. The excellent chemical stability of TiAlN coating and oxidation resistance performance made contribution to prevent oxidation wear. Another reason was that boring temperature was lower than oxidation temperature.

scholarly journals Influence of Cutting Parameters on Surface Roughness for Wet and Dry Turning Process

2011 ◽  
Vol 471-472 ◽  
pp. 233-238 ◽  
Author(s):  
Muhammad Yusuf ◽  
Khairol Anuar ◽  
Napsiah Binti Ismail ◽  
Shamsuddin Sulaiman
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Fractional Factorial ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Turning Process ◽  
Dry Cutting ◽  
Dry Turning ◽  
Coated Carbide

This paper presents a study of the quality of a surface roughness model for mild steel with coated carbide cutting tool on turning process. The experiments were carried out under wet and dry cutting conditions. The model is developed based on cutting speed, feed and depth of cut as the parameters of cutting process. This research applies the fractional factorial design of experiment approach to studied the influence of cutting parameters on surface roughness. The measured results were collected and analyzed using commercial software package called Minitab. Analysis of variances is used to examine the influence of turning factors and factor interactions on surface roughness. The result indicated that, there are inherent differences in surface roughness between wet and dry cutting process with the same parameters process model. Analysis of variance was found that feed parameter is the most significant cutting parameter, which influences the surface roughness. The most significant interactions were found between cutting speed and feed parameters for dry turning process. Therefore is a significant effect of using combination of the fluid for cooling the cutting operation.

scholarly journals An Investigation on Optimum Process Parameters in Terms of Surface Roughness for Turning Titanium Alloy Ti-6Al-4V Using Coated Carbide

2019 ◽  
Vol 4 (4) ◽  
pp. 137-145
Author(s):  
Abdul Md Mazid ◽  
Md. Shahanur Hasan ◽  
Kazi Badrul Ahsan
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Real Life ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ti Alloys ◽  
Machined Parts ◽  
Coated Carbide ◽  
Coated Carbide Tools

The quality of machined parts and the productivity of machining that leads to economic sustainability.  These factors are also vital for machinability improvement for materials, as well as, for economically sustainable manufacturing. Due to their poor machinability titanium alloys (Ti-alloys) are categorised as difficult-to-machine materials. For the same reason products made of Ti-alloys are highly expensive and are used only in strategic and sophisticated industries.  A series of real-life experimental investigations was carried out to reveal the economic optimal zones of machining parameters that can produce the best possible surface roughness in machining Ti-6Al-4V alloy, using the coated carbide cutting tools, in shortest period of operation time. As the output of the research, for using the coated carbide tools for machining the investigated Ti-alloy, optimal zones of cutting speed, feed rate and depth of cut have been proposed and presented in graphical format. The current research revealed that all three groups (with nose radius Nr = 0.4, 0.8, and 1.2 mm) of coated carbide tools are capable to produce best surface finish, ranging between Ra = 0.5 - 1.0 µm, with cutting speed starting at V = 60 m/min and beyond at least up to V = 250 m/min while keeping the feed rate and depth of cut as constants as f = 0.1 mm/rev and d = 0.5 mm. The data on the graphs may help researchers, engineers and manufacturers to select optimal economic cutting speed, feed rate and depth of cut to achieve a certain level of surface roughness of machined components as assigned by the product designer on the part drawing. This reduces the production cost substantially, reduces number of defect products and improves product quality for machined parts.

Cutting Forces and Tool Wear in Dry Milling of Ti6Al4V

2012 ◽  
Vol 565 ◽  
pp. 454-459 ◽  
Author(s):  
Yun Chen ◽  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Workpiece Material ◽  
Tool Wear Mechanism ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Cutting Speeds

Titanium alloys are difficult-to-cut materials. This paper presents an experimental study of the effects of different cutting conditions and tool wear on cutting forces in dry milling Ti6Al4V with coated carbide inserts. The experimental results show that the peak forces increase with the increase in the feed rate and depth of cut. With the cutting speed increment in the range from 50 m/min to 150 m/min the peak forces decrease, while at further higher cutting speeds investigated peak forces increase. The decrease of the peak forces is due to thermal softening of the workpiece material and the increase is because of the strain hardening rate of Ti6Al4V. The tool wear experiment reveals that the major tool wear mechanism is the flank wear. The variations of the peak forces are caused by both the tool wear propagation and the thermal effects.

Reliability and economic analysis in sustainable machining of Monel 400 alloy

2021 ◽  
pp. 095440622098681
Author(s):  
Ashwani Tayal ◽  
Nirmal Singh Kalsi ◽  
Munish Kumar Gupta ◽  
A Garcia-Collado ◽  
Murat Sarikaya
Keyword(s):  
Surface Roughness ◽  
Economic Analysis ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Turning ◽  
Sustainable Machining ◽  
Coated Carbide Tool ◽  
Prime Concern ◽  
Coated Carbide

Engineering field nurtures a variety of superalloys and its wide applications due to the inherent properties of such material. The prime concern of working engineers is to explore reliability, quality, economy, and machinability analysis of these superalloys. In this work, sustainable machining of Monel 400superalloy using PVD multilayer coated carbide tool under dry turning was studied. Surface roughness (Ra, Rz, and Rq), power (P) and cutting force (Fc) were addressed as responses. The subsequent effect of cutting speed, feed and depth of cut on the responses was explored through response surface methodology (RSM), statistical analysis of variance (ANOVA) and multiple regression analysis. Details of tool wear was observed via scanning electron microscope (SEM) to know the cutting behavior at interface. Further, the reliability and economic analysis were performed to substantiate the feasibility of cutting insert. The investigation reveals that surface roughness was affected by feed and cutting speed. The increase in cutting speed uncovers lower cutting forces with improved surface finish during dry turning which further reduces the power requirement. The economic analysis shows unit production time and unit production cost based on a single insert PVD coated carbide tool under optimum value condition. The reliability analysis exposes the meantime to repair (MTTR) (5 min), mean time between failure (MTBF) (28 min), availability (84.8%), failure rate (0.03), and reliability (80.5%) for the production system.

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.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

Statistical Study and Multi-Response Optimization of Cutting Parameters for Dry Turning Stainless Steel AISI 316L Using Cermet Tool

2020 ◽  
Vol 36 ◽  
pp. 28-46
Author(s):  
Youssef Touggui ◽  
Salim Belhadi ◽  
Salah Eddine Mechraoui ◽  
Mohamed Athmane Yallese ◽  
Mustapha Temmar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Aisi 316L ◽  
Cutting Power ◽  
Dry Turning ◽  
Optimization Of Cutting Parameters

Stainless steels have gained much attention to be an alternative solution for many manufacturing industries due to their high mechanical properties and corrosion resistance. However, owing to their high ductility, their low thermal conductivity and high tendency to work hardening, these materials are classed as materials difficult to machine. Therefore, the main aim of the study was to examine the effect of cutting parameters such as cutting speed, feed rate and depth of cut on the response parameters including surface roughness (Ra), tangential cutting force (Fz) and cutting power (Pc) during dry turning of AISI 316L using TiCN-TiN PVD cermet tool. As a methodology, the Taguchi L27 orthogonal array parameter design and response surface methodology (RSM)) have been used. Statistical analysis revealed feed rate affected for surface roughness (79.61%) and depth of cut impacted for tangential cutting force and cutting power (62.12% and 35.68%), respectively. According to optimization analysis based on desirability function (DF), cutting speed of 212.837 m/min, 0.08 mm/rev feed rate and 0.1 mm depth of cut were determined to acquire high machined part quality

The Effects of Cutting Parameters on Work-Hardening of Milling Invar 36

2015 ◽  
Vol 1089 ◽  
pp. 373-376
Author(s):  
Xing Wei Zheng ◽  
Guo Fu Ying ◽  
Yan Chen ◽  
Yu Can Fu
Keyword(s):  
Work Hardening ◽  
Lattice Distortion ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Metallographic Structure ◽  
Metallographic Observation ◽  
Coated Carbide ◽  
Carbide Insert ◽  
Axial Depth

An experiment of face milling of Invar36 was conducted by using coated carbide insert, the microhardness was tested and the metallographic structure was observed to figure out the principles of work-hardening. The results showed that the depth of work-hardening ranges from 80μm to 160μm among the parameters selected in the experiments. The degree and the depth of work-hardening were significantly affected by the axial depth of cut and feed per tooth. The degree and the depth of work-hardening showed a tendency to increase with the increase of the axial depth of cut and feed per tooth. Compared with the axial depth of cut and feed per tooth, cutting speed had less influence on the degree and depth of work-hardening. The degree and depth of work- hardening decreased slowly with the increase of cutting speed. Metallographic observation showed that work-hardening layer consisted of the thermal force influenced layer and the force influenced layer, while the amorphous metallographic structure was observed in the thermal force influenced layer, and lattice distortion was observed in the force influenced layer.

Optimum Cutting Speed for Machining Stainless Steel with Coated Carbide Tools

2006 ◽  
Vol 7 (3-4) ◽  
pp. 201-206
Author(s):  
Ahsan Ali Khan, ◽  
Roshaliza Bt Hamidon, ◽  
Muhariyanti Bt Che Mat,
Keyword(s):  
Stainless Steel ◽  
Cutting Speed ◽  
Optimum Cutting ◽  
Coated Carbide ◽  
Coated Carbide Tools
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