Heat and Temperatures in Machining: Effects and Significance

2012 ◽  
Vol 622-623 ◽  
pp. 1550-1553
Author(s):  
Rajesh Patil ◽  
Vilas Kalamkar ◽  
Hari Vasudevan
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Surface Characteristics ◽  
Contact Length ◽  
Machined Surface ◽  
Temperature Changes ◽  
Economic Problems ◽  
Highly Sensitive ◽  
Tool Wear Mechanisms ◽  
Finish Hard Turning

Heat generated in machining is significant to study, as number of technical and economic problems has root into it. The high temperatures on cutting tool needs better understanding of contact processes at tool-chip ,tool-workpiece interfaces. The contact length at tool-chip interface is significant to study as it governs the heat moving to the tool as well as many tribological conditions like stresses, tool wear. Understanding of Tool-workpiece interface is significant as it affects the heat moving to workpiece, tool, chip as well as tool flank wear and major machined surface characteristics. Non-sliding type tool wear mechanisms which are highly sensitive to temperature changes are important to study. The latest trends of using High Speed Machining, Dry and Near Dry Machining, Finish hard turning results in more heat generation demanding significant understanding of effect of heat generated and temperatures.

KT5331AS0 and 45 Steel Milling Comparison of Surface Characteristics

2011 ◽  
Vol 66-68 ◽  
pp. 2062-2068
Author(s):  
Jian Sheng Ding ◽  
Yang Ping Xu
Keyword(s):  
Mass Fraction ◽  
High Speed ◽  
Steel Surface ◽  
Surface Composition ◽  
Surface Hardness ◽  
Surface Oxidation ◽  
Surface Characteristics ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Cooling Conditions

To study the surface composition, hardness, microstructure of the machined surface in KT5331AS0 and 45 steel at different cutting parameters and cooling conditions. The results show that: in the cutting process the mass fraction of W in KT5331AS0 steel surface were reduced to varying degrees, the basic chemical composition of 45 steel surface did not change; When KT5331AS0 steel in the high-speed, higher feed rate, it will be cause surface hardness increasing, however the hardness of 45 steel have no regular variation; 45 steel will have greater depth of the torn surface after milling, tearing a wider range, more obvious surface oxidation.

Surface Integrity of Die Material in High Speed Hard Machining, Part 1: Micrographical Analysis

1999 ◽  
Vol 122 (4) ◽  
pp. 620-631 ◽  
Author(s):  
T. I. El-Wardany ◽  
H. A. Kishawy ◽  
M. A. Elbestawi
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
Tool Steel ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Conditions ◽  
Metallographic Analysis ◽  
Tool Geometry ◽  
Machined Surface ◽  
Geometrical Defects

The effects of cutting conditions and tool wear on chip morphology and surface integrity during high speed machining of D2 tool steel (60–62 Hrc) are investigated experimentally and analytically in this paper. Polycrystalline Cubic Boron Nitride (PCBN) tools are used in this investigation. The chips and the subsurface of the workpiece are examined using optical and scanning electron microscopy. Microhardness measurements are performed on the surface and subsurface of the workpiece. The X-ray diffraction technique is used to measure the residual stresses induced in the machined surface. The paper is divided into two parts. Part 1 presents the results obtained from the micrographical analysis of the chips and the surfaces produced. Part 2 deals with microhardness and residual stresses of the machined surface. The micrographical analysis of the chips produced shows that different mechanisms of chip formation exist depending on the magnitude of the cutting pressure and tool wear. Saw toothed chips are produced during the machining of D2 tool steel if the cutting pressure exceeds approximately 4000 MPa. The metallographic analysis of the surface produced illustrates the damaged surface region that contains geometrical defects and changes in the subsurface metallurgical structure. The types of surface damage are dependent on the cutting conditions, tool geometry and the magnitude of the wear lands. [S1087-1357(00)00104-0]

Influence Characteristics of Tool Vibration and Wear on Machined Surface Topography in High-Speed Milling

2014 ◽  
Vol 800-801 ◽  
pp. 585-589
Author(s):  
Bin Jiang ◽  
Guang Lei Cao ◽  
Ming Hui Zhang ◽  
Shou Zheng Sun ◽  
Xuan Chi Liu
Keyword(s):  
Tool Wear ◽  
Surface Topography ◽  
High Speed ◽  
Three Dimensional ◽  
Cutting Parameters ◽  
Three Dimensional Model ◽  
Machined Surface ◽  
Tool Vibration ◽  
Key Factor ◽  
Vibration Measuring

Existing research on machined surface topography, only consider its response to vibration or wear certain factors, both vibration and wear impact on machined surface topography exist ambiguity and uncertainty, it cannot solve the design conflicts of machined surface topography. For this, this paper analyzes blade installation error, tool wear, vibration and deformation to reveal effects of tip space trajectory, build a three-dimensional model of machined surface topography in simulation, extract its characteristic parameters, by simulation of different amplitudes and wear, found that axis amplitude is a key factor affecting surface residual height, flank wear affects contour distribution distance significantly, by specimen milling experiments, use vibration measuring instrument and ultra-depth microscopy to obtain vibration, wear characteristics and machined surface topography parameters under different cutting parameters, then use the gray system theory to get correlation analysis of the test data, results showed that the influence of tool wear on machined surface topography is prominent than tool vibration.

Wear Mechanisms of Ceramic Tools in High-Speed Turning of Superalloy GH2132

2013 ◽  
Vol 589-590 ◽  
pp. 23-27 ◽  
Author(s):  
Dong Wang ◽  
Jun Zhao ◽  
Xiao Xiao Chen ◽  
Yong Hui Zhou
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
High Speed ◽  
Cutting Tool ◽  
Element Distribution ◽  
Cutting Condition ◽  
Dry Cutting ◽  
High Speed Turning ◽  
Ceramic Cutting Tool ◽  
Tool Wear Mechanisms

An experimental investigation of wear mechanisms in high-speed turning of superalloy GH2132 with Al2O3-based ceramic was conducted under dry cutting condition. The tool wear mechanisms were characterized by observation of tool wear morphology using scanning electron microscopy (SEM) and detection of the element distribution of the worn tool surface utilizing energy dispersive X-ray spectroscopy (EDS). The results of turning experiments indicated that the major wear mechanisms of the ceramic cutting tool were synergistic interaction between abrasive wear and adhesive wear, and meanwhile the micro-chipping was also observed. It is also shown that cutting distance of the Al2O3-TiC ceramic cutting tool at the speed of 420 m/min was higher than that of the speed of 360 m/min and 540 m/min.

Identification of Subsurface Deformation in Machining of Inconel 718

2011 ◽  
Vol 117-119 ◽  
pp. 1681-1688 ◽  
Author(s):  
Jin Ming Zhou ◽  
Volodymr Bushlya ◽  
Ru Lin Peng ◽  
Jan Eric Stahl
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Strain Analysis ◽  
Cutting Parameters ◽  
Correct Prediction ◽  
Process Conditions ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
Subsurface Region

There is considerable industrial significance to understand the nature of subsurface deformation under the machined surface for correct prediction of surface properties in machined components based upon the machined conditions and material behaviors that give rise to them. In this study, high speed machining of Inconel 718 was carried with whisker reinforced ceramic cutting tool under different conditions of tool wear, coolant state and cutting parameters. The objective of the present investigation was to determine the effect of both cutting parameters and tool wear on the plastic deformation in the subsurface region of Inconel 718 after the finishing machining with above process conditions. The surface and subsurface region of machined specimens were examined using a high resolution scan electron microscope (HRSEM) and EBSD technique, microhardness measurements were also conducted on the test samples, accordingly plastic strain analysis were carried out.

Research Progress of High Speed Cutting for SiCp_Al Composite Materials

2014 ◽  
Vol 800-801 ◽  
pp. 3-8
Author(s):  
Yang Bai ◽  
Pei Quan Guo ◽  
Ning Fan
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
Surface Quality ◽  
High Speed ◽  
Surface Defects ◽  
Cutting Tools ◽  
Research Progress ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Machined Surface Quality

Summarized the research and development of high speed machining of SiCp/Al composites. Emphasized the research status of high speed cutting of SiCp/Al composite materials, including machined surface quality and tool wear condition. Machined surface quality contains surface roughness and surface defects. The tool wear conditions are different because of different types of cutting tools, but the wear of the rake face, the rear face and the cutting edge are all involved.

Experiment Study of Tool Wear and Surface Integrity in High Speed Milling of a New Damage-Tolerant Titanium Alloy

2012 ◽  
Vol 723 ◽  
pp. 177-181 ◽  
Author(s):  
Qi Shi ◽  
Yin Fei Yang ◽  
Ning He ◽  
Liang Li ◽  
Wei Zhao
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Integrity ◽  
High Speed ◽  
White Layer ◽  
Cutting Tools ◽  
Machined Surface ◽  
High Speed Milling ◽  
Metallurgical Structure ◽  
Damage Tolerant

TC4-DT is a new damage-tolerant titanium alloy. In the paper, a series of experiments on tool wear and surface integrity in high speed milling of the alloy were carried out. The tool lives of different tool materials were studied and the wear mechanism of cutting tools was also investigated. Then surface integrity, including surface roughness, microhardness and metallurgical structure was studied and analyzed in high speed milling at different tool wear status. Results showed that K10 is the most suitable cutting tool after considering a combination of factors. And good surface integrity could be obtained in high speed milling of TC4-DT under all cutting situations. In addition, even with acutely worn stages, there has been no so-called serious hardening layer (or white layer) according to the study of microhardness and metallurgical structure beneath the machined surface.

Experimental Study on the Milling of a High Strength Titanium Alloy

2004 ◽  
Vol 471-472 ◽  
pp. 731-735 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu ◽  
Ying Fei Ge ◽  
Yu Can Fu
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Design Method ◽  
Orthogonal Experiment ◽  
High Strength ◽  
Machined Surface ◽  
Heavy Load ◽  
Metallographic Examination

A series of experiments were carried out on normal and high speed milling of a high strength titanium alloy (TA15). TA15 is a close alpha titanium alloy strengthened by solid solution with Al and other component. It is often used to make large structural parts in airplane and welded parts subject to heavy load. The tool life of several typical types of cutter commonly used in the milling of titanium alloy was studied by the orthogonal experiment design method. After multi-element regression analysis, the empirical equation of the tool life was stablished. The milling force and temperature were measured under different cutting conditions and tool wear status. The knowledge is useful to further understand and analysis of the cutting mechanism, machining quality and tool wear. The study on the machined surface integrity includes the following content: surface roughness, metallographic examination, work hardening and residual stress.

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