Investigation of Tool Failure Modes and Machining Disturbances Using Monitoring Signals

The ACCENT Project (FP7-AAT-2007-RTD-1) will allow the European Aero Engine manufacturers to improve their competitiveness by applying adaptive control techniques to the manufacturing of their components. For the critical rotating parts of aircraft engines, the surface integrity generated after machining is a key factor on the life cycle. In this context, one particular attention has to be carried out on tool condition. The aim of this paper is to define a monitoring approach able to detect the tool condition and machining disturbances. The main failure modes characterizing this particular Nickel base drilling and the apparition of embedded chips over the machined surface were identified. By experimental techniques, cartography of failure modes was performed. The results show that flank wear and notch are the main failure modes limiting the tool life. For some cutting conditions, the tool failure occurs after the first hole due to the important cutting forces. Some interesting combinations are made between the spindle current/accelerometers/ thrust force and flank wear, tool breakage and notch. Before these correlations, a detailed signal analysis was performed, considering different disturbing phenomena, such as chips evacuation problem. Finally, a “synopsis” for process monitoring is proposed, considering the analyzed phenomena.

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Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 2: Effect of tool failure modes

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415600011 ◽

2015 ◽

Vol 231 (9) ◽

pp. 1575-1586 ◽

Cited By ~ 11

Author(s):

Shoujin Sun ◽

Milan Brandt ◽

Matthew S Dargusch

Keyword(s):

Plastic Deformation ◽

Tool Wear ◽

Failure Modes ◽

Flank Wear ◽

Cutting Tools ◽

Cutting Edge ◽

Machined Surface ◽

Tool Failure ◽

Geometric Ratio ◽

Cutting Speeds

Variation in the geometric and surface features of segmented chips with an increase in the volume of material removed and tool wear has been investigated at cutting speeds of 150 and 220 m/min at which the cutting tools fail due to gradual flank wear and plastic deformation of the cutting edge, respectively. Among the investigated geometric variables of the segmented chips, slipping angle, undeformed surface length, segment spacing, degree of segmentation and chip width showed the different variation trends with an increase in the volume of material removed or flank wear width, and achieved different values when tool failed at different cutting speeds. However, the chip geometric ratio showed a similar variation trend with an increase in the volume of material removed and flank wear width, and achieved the similar value at the end of tool lives at cutting speeds of both 150 and 220 m/min regardless of the different tool failure modes. Plastic deformation of the tool cutting edge results in severe damage on the machined surface of the chip and significant compression deformation on the undeformed surface of the chip.

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Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

Metals ◽

10.3390/met9080885 ◽

2019 ◽

Vol 9 (8) ◽

pp. 885

Author(s):

Guangyue Wang ◽

Xianliang Zhou ◽

Xuefeng Wu ◽

Jing Ma

Keyword(s):

Failure Mechanism ◽

High Speed ◽

Failure Modes ◽

Flank Wear ◽

Cutting Speed ◽

Machining Efficiency ◽

Tool Failure ◽

Low Speed ◽

High Cutting Speed ◽

Pcbn Tools

The polycrystalline cubic boron nitride (PCBN) milling tool can be used in the mold industry to replace cemented carbide tools to improve machining efficiency and quality. It is necessary to study the tool wear and failure mechanism to increase machining efficiency and extend tool life. Cr12MoV is used to analyze the failure form of PCBN tools in the interrupted cutting of hardened steels at low and high speed conditions in milling experiments. Experimental results show that the failure forms of PCBN tools include chipping and flank wear at low speed, and the failure modes at high speed are flank wear, the surface spalling of the rake face, and the fatigue failure on the flank face. The failure mechanism of different failure forms is analyzed by observing the surface morphology of the tool and using the theory of fracture mechanics. The results show that a high cutting speed should be selected to avoid the early damage of low speed and achieve better application of PCBN tools. At high cutting speed, tool failure is mainly caused by mechanical wear, diffusion wear, and oxidation wear. Moreover, a fatigue crack will occur at the cutting edge on the chamfered tool under thermal–mechanical coupling because of the intergranular fracture of the CBN grain and binder. A large area of accumulated fatigue damage may appear due to the influence of alternating mechanical stress and thermal stress. Finally, the control method to avoid tool failure is presented.

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Tool Life and Flank Wear of Physical Vapour Deposited TiAlN Multilayer Coated Carbide End Mill Inserts when Machining AISI D2 Hardened Steel under Dry Cutting Condition

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.903.9 ◽

2014 ◽

Vol 903 ◽

pp. 9-14

Author(s):

Nor Ain Jamil Hosni ◽

Mohd Amri Lajis ◽

Noor Hakim Rafai

Keyword(s):

Tool Life ◽

Material Removal ◽

Failure Modes ◽

Flank Wear ◽

Cutting Speed ◽

Depth Of Cut ◽

Radial Depth ◽

Aisi D2 ◽

Wear Tool ◽

Coated Carbide

This study investigates the tool wear of PVD TiAlN multilayer coated end mill inserts when machining AISI D2 hardened steel in dry conditions. The experiment tests consisting three levels of cutting speed, Vc (80, 100, 120 m/min) and three levels of radial depth of cut, ae (3, 4, 5 mm) was used for the study. The PVD TiAlN coated carbide insert performs satisfactory under the conditions tested, as reasonable tool life is recorded. By linking the machining tests and tool life curves, the wear behaviour of the coated insert was described. It is observed that wear of the tool mainly occurred on the flank wear. Tool life decreasing and volume material removal (VMR) increasing as cutting speed and radial depth of cut increased due to higher temperature generated and contact area immerse, respectively. Tool failure modes and wear mechanisms were examined at various cutting parameters. Built-up edge (BUE), groove and micro-chipping were found to be the predominant tool failure modes for cutting tools. The highest volume material removal, VMR attained was 3750 mm3, meanwhile the higest tool life, TL was 9.69 min.The combination of cutting conditions that gave the best response for different components of tool wear, tool life and surface integrity.

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Tool Condition Monitoring in Turning by Applying Machine Vision

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4031770 ◽

2015 ◽

Vol 138 (5) ◽

Cited By ~ 14

Author(s):

Samik Dutta ◽

Surjya K. Pal ◽

Ranjan Sen

Keyword(s):

Regression Models ◽

Flank Wear ◽

Voronoi Tessellation ◽

Support Vector ◽

Discrete Wavelet ◽

Machined Surface ◽

Tool Flank Wear ◽

Tool Condition ◽

Occurrence Matrix ◽

Surface Images

In this paper, a method for predicting progressive tool flank wear using extracted features from turned surface images has been proposed. Acquired turned surface images are analyzed by using texture analyses, viz., gray level co-occurrence matrix (GLCM), Voronoi tessellation (VT), and discrete wavelet transform (DWT) based methods to obtain information about waviness, feed marks, and roughness from machined surface images for describing tool flank wear. Two features from each texture analyses are extracted and fed into support vector machine (SVM) based regression models for predicting progressive tool flank wear. Mean correlation coefficient between the measured and predicted tool flank wear is found as 0.991.

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Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.191 ◽

2014 ◽

Vol 800-801 ◽

pp. 191-196

Author(s):

Bin Zhao ◽

Han Lian Liu ◽

Chuan Zhen Huang ◽

Bin Zou ◽

Hong Tao Zhu

Keyword(s):

Surface Roughness ◽

Tool Life ◽

Failure Modes ◽

Flank Wear ◽

Cutting Performance ◽

Cemented Carbide ◽

Nickel Based Superalloy ◽

Coated Tool ◽

Optimal Cutting Parameters ◽

Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

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Tool condition monitoring: unscented Kalman filter for tool flank wear estimation in turning of Inconel 718

Machining Science and Technology ◽

10.1080/10910344.2020.1855650 ◽

2021 ◽

pp. 1-13

Author(s):

Chandrani Sadhukhan ◽

Swarup Kumar Mitra ◽

Ranjib Biswas ◽

Mrinal Kanti Naskar

Keyword(s):

Kalman Filter ◽

Condition Monitoring ◽

Inconel 718 ◽

Flank Wear ◽

Unscented Kalman Filter ◽

Tool Condition Monitoring ◽

Tool Flank Wear ◽

Tool Condition

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Analysis of Tool Wear: Part II: Applications of Flank Wear Models

Journal of Engineering for Industry ◽

10.1115/1.3427693 ◽

1970 ◽

Vol 92 (1) ◽

pp. 109-114 ◽

Cited By ~ 6

Author(s):

A. Bhattacharyya ◽

A. Ghosh ◽

Inyong Ham

Keyword(s):

Tool Wear ◽

Critical Points ◽

Quantitative Assessment ◽

Inflection Point ◽

Flank Wear ◽

Cemented Carbides ◽

Temperature Sensitive ◽

Tool Failure ◽

Cutting Speeds ◽

Asme Paper

For machining with cemented carbides and ceramics, a quantitative assessment of tool failure at the flank for establishing “limit criterion” is necessary. The arbitrarily chosen flank wear limit for all cutting speeds is not valid at higher cutting speeds because of the earlier appearance of the “inflection point” which is often taken as criterion of flank-failure. In this paper, proceeding from the basic physical model of flank wear described in Part I of the paper (ASME Paper No. 68—WA/Prod-5), tool-life relations in the form of Taylor’s equations have been theoretically developed, the parameters of which have been compared with, experimental results. Further, the critical points of inflexion where the flank-wear characteristic enters temperature sensitive region resulting in accelerated wear have been uniquely defined. The location of these critical points have also been verified experimentally.

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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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A Design Environment for Performance Modeling and Analysis of Aero Engine Lubrication Systems

ASME 2013 Gas Turbine India Conference ◽

10.1115/gtindia2013-3542 ◽

2013 ◽

Author(s):

Prasath Mahendiran ◽

Bommaian Balasubramanian ◽

Muralidhar Manavalan ◽

Adithya Rao

Keyword(s):

Performance Modeling ◽

Failure Modes ◽

System Modeling ◽

Simulation Software ◽

Lubrication System ◽

Design Environment ◽

Report Generation ◽

Modeling And Analysis ◽

Aero Engine ◽

Performance Modeling And Analysis

This paper presents the overview and capability of design Environment for performance modeling and analysis of aero engine lubrication systems. The design environment is implemented as an intuitive and easy to use toolbox implemented within the commercial off-the-shelf (COTS) simulation software environment MATLAB/Simulink®. The toolbox consists of a library of predefined reusable/generic lubrication system components like flow resistance elements, pumps and orifice. The component behavior is modeled mathematically using first principles and component characteristics. The developed components have been extensively verified & validated with actual hardware test data covering multiple test points in the flight envelope and also different failure modes of the system. The verification & validation methodology and the results of the component tests, is not the subject of the paper. The aero engine lubrication system is modeled by connecting the components drawn from the library to form a network consisting of nodes and flow paths. The solver implemented computes the unknown pressure and flow values in the lubrication circuit. The design environment has been used to perform steady state performance analysis of aero engine lubrication system. It has additional capability to perform parametric studies, trade studies, design exploration, analyzing simulation results and automated report generation, which will be described in the paper. The flexible software architecture and modular programming techniques has delivered the significant benefit of component models reuse. The generic nature of the toolbox can be exploited to perform system modeling and analysis of any hydraulic system.

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