The Dependency of the Tool Life on the Cutting Speed at the Investigation of the Tool with Specific Geometry

2012 ◽  
Vol 622-623 ◽  
pp. 347-351 ◽  
Author(s):  
Katarina Monkova ◽  
Sergej Hloch
Keyword(s):  
Regression Analysis ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Specific Geometry ◽  
Graphical Presentation

The aim of the paper is to find the dependency of tool life on the cutting speed at investigation of two selected tools with linear cutting edge not parallel with the workpiece axis. The tools differ in their geometry. Conditions of experiments, used equipments and some problems, which are necessary to solve from the standpoint of machining technology with regard to tools are described in the article, too. The experimental obtained data were statistical processed by the method of regression analysis. The results are arranged into the graphical presentation, which enables the comparison of tool life at the same cutting speed and consequently the choice of the most suitable geometry of tool at the machining in specific conditions.

The Comparison of Surface Roughness Characteristics Achieved by the Machining with Conventional and Unconventional Geometry of Tools

2012 ◽  
Vol 622-623 ◽  
pp. 352-356 ◽  
Author(s):  
Peter Monka
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Profile ◽  
Operation Time ◽  
Cutting Edge ◽  
Technological Operation ◽  
Profile Characteristics ◽  
Machining Productivity

The paper deals with the experiments realized by means of cutting tool with linear cutting edge not parallel with the axis of the workpiece in order to be observed the suitable values of surface roughness characteristics in dependency on the feed and cutting speed. During experiments were machined three types of steels. Acquired data were statistical processed by regression analysis. The results of the measurements show that the investigated cutting tool enables to secure the same values of surface profile characteristics of steels as a classical cutting tool at finishing with the significant increase of the feed per revolution. It directly influences length of the technological operation time which is several times shortened and so the machining productivity can increase.

The Effect of Cut Tool Geometric Parameters on Tool Tear of Machining Nickel-Base GH4169 Super Alloys

2010 ◽  
Vol 37-38 ◽  
pp. 1457-1461 ◽  
Author(s):  
Zhao Peng Hao ◽  
D. Gao ◽  
R.D. Han
Keyword(s):  
Tool Life ◽  
Cutting Speed ◽  
High Strength ◽  
Rake Angle ◽  
Geometric Parameters ◽  
Cutting Edge ◽  
Factors Affecting ◽  
Edge Angle ◽  
Coated Tools ◽  
Nickel Base

Nickel-based super alloy GH4169 has been widely used in aerospace industry because of its good mechanical properties under high temperature. However, it is difficult to machine for its high strength, poor thermal conductivity and serious work-hardening. The effects of tool geometric parameters on tool life are studied by machining experiments using YG8 tools with different cutting edge angle in this paper. The tool with cutting edge angle 45°has longer tool life than 75°. The cutting experiments have been carried out using TiAlN (PVD) coated tools (AC520U) with different rake angle. It shows that the tool life with rake angle 9° were increased by 50% and 25% compared to tool with rake angle 3°and 6° when cutting speed is 30m/min. The tool with rake angle 9° is not suitable for cutting GH4169 when cutting speed is more than 35m/min. The results show that geometric parameter of cutting tool is one of the important factors affecting tool life.

A Stochastic Tool-Life Model

1981 ◽  
Vol 103 (1) ◽  
pp. 126-130 ◽  
Author(s):  
S. Rossetto ◽  
A. Zompi
Keyword(s):  
Stochastic Model ◽  
Failure Rate ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Model Based ◽  
Life Model ◽  
Theoretical Standpoint

A tool-life model based on the assumption that wear and fracture are the causes of tool death is re-examined from the theoretical standpoint, and extended to include the effect of cutting speed on the fracture-induced failure rate. A stochastic model for multi edge cutting tools is also proposed. This enables the overall statistics to be derived from the data for each individual cutting edge.

scholarly journals Optimization of CNC End Milling Process Parameters of Low-Carbon Mold Steel Using Response Surface Methodology and Grey Relational Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
R. Suresh Kumar ◽  
S. Senthil Kumar ◽  
K. Murugan ◽  
B. Guruprasad ◽  
Sreekanth Manavalla ◽  
...  
Keyword(s):  
Regression Analysis ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Machining Process ◽  
Depth Of Cut ◽  
Low Carbon ◽  
Box Behnken Design ◽  
Cnc End Milling

The manufacturing sectors are consistently striving to figure out ways to minimize the consumption of natural resources through rational utilization. This is achieved by a proper understanding of every minute influence of parameters on the entire process. Understanding the influencing parameters in determining the machining process efficacy is inevitable. Technological advancement has drastically improved the machining process through various means by providing better quality products with minimum machining cost and energy consumption. Specifically, the machining factors such as cutting speed, spindle speed, depth of cut, rate of feed, and coolant flow rate are found to be the governing factors in determining the economy of the machining process. This study is focused on improving the machining economy by enhancing the surface integrity and tool life with minimum resources. The study is carried out on low-carbon mold steel (UNS T51620) using Box–Behnken design and grey regression analysis. The optimized multiobjective solution for surface roughness (Ra), material removal rate (MRR), and power consumed (Pc) and tool life is determined and validated through the confirmatory run. The optimized set of parameters in Box–Behnken design and grey regression analysis with that of confirmatory runs shows a 10% deviation that proves the reliability of the optimization techniques employed.

An Experimental Investigation of the Influence of Cutting-Edge Geometry on the Machinability of Compacted Graphite Iron

2013 ◽  
Vol 3 (1) ◽  
pp. 1-25 ◽  
Author(s):  
Varun Nayyar ◽  
Md. Zubayer Alam ◽  
Jacek Kaminski ◽  
Anders Kinnander ◽  
Lars Nyborg
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Tool Geometry ◽  
Compacted Graphite Iron ◽  
Compacted Graphite ◽  
Edge Geometry ◽  
Area Of Interest

Compacted graphite iron (CGI) is considered as the potential replacement of flake graphite iron (FGI) for the manufacturing of new generation high power diesel engines. Use of CGI, that have higher strength and stiffness as compared to FGI, allows engine to perform at higher peak pressure with higher fuel efficiency and lower emission rate. However, not only for its potential, CGI is of an area of interest in metal cutting research because of its poor machinability as compared to that of FGI. The higher strength of CGI causes a faster tool wear rate in continuous machining operation even in low cutting speed as compared to that for FGI. This study investigated the influence of cutting edge geometry at different cutting parameters on the machinability of CGI in terms of tool life, cutting force and surface roughness and integrity in internal turning operation under wet condition. It has been seen that the cutting edge radius has significant effect on tool life and cutting forces. The results can be used to select optimum cutting tool geometry for continuous machining of CGI.

scholarly journals Machining of Titanium Metal Matrix Composites: Progress Overview

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Metal Matrix ◽  
Dust Emission ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Machining Processes ◽  
Tool Wear Mechanisms

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).

scholarly journals Experimental Study of tool Wear Mechanisms in Conventional and High Pressure Coolant Assisted Machining of Titanium Alloy Ti17

2013 ◽  
Vol 554-557 ◽  
pp. 1961-1966 ◽  
Author(s):  
Yessine Ayed ◽  
Guenael Germain ◽  
Amine Ammar ◽  
Benoit Furet
Keyword(s):  
High Pressure ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Cutting Forces ◽  
Cutting Edge ◽  
Rake Face ◽  
High Pressure Coolant

Titanium alloys are known for their excellent mechanical properties, especially at high temperature. But this specificity of titanium alloys can cause high cutting forces as well as a significant release of heat that may entail a rapid wear of the cutting tool. To cope with these problems, research has been taken in several directions. One of these is the development of assistances for machining. In this study, we investigate the high pressure coolant assisted machining of titanium alloy Ti17. High pressure coolant consists of projecting a jet of water between the rake face of the tool and the chip. The efficiency of the process depends on the choice of the operating parameters of machining and the parameters of the water jet such as its pressure and its diameter. The use of this type of assistance improves chip breaking and increases tool life. Indeed, the machining of titanium alloys is generally accompanied by rapid wear of cutting tools, especially in rough machining. The work done focuses on the wear of uncoated tungsten carbide tools during machining of Ti17. Rough and finish machining in conventional and in high pressure coolant assistance conditions were tested. Different techniques were used in order to explain the mechanisms of wear. These tests are accompanied by measurement of cutting forces, surface roughness and tool wear. The Energy-dispersive X-ray spectroscopy (EDS) analysis technique made it possible to draw the distribution maps of alloying elements on the tool rake face. An area of material deposition on the rake face, characterized by a high concentration of titanium, was noticed. The width of this area and the concentration of titanium decreases in proportion with the increasing pressure of the coolant. The study showed that the wear mechanisms with and without high pressure coolant assistance are different. In fact, in the condition of conventional machining, temperature in the cutting zone becomes very high and, with lack of lubrication, the cutting edge deforms plastically and eventually collapses quickly. By contrast, in high pressure coolant assisted machining, this problem disappears and flank wear (VB) is stabilized at high pressure. The sudden rupture of the cutting edge observed under these conditions is due to the propagation of a notch and to the crater wear that appears at high pressure. Moreover, in rough condition, high pressure assistance made it possible to increase tool life by up to 400%.

Drehen von ausferritischem Gusseisen*/Turning of austempered ductile iron – Impact of inhomogeneous cutting edge geometry on wear mechanism and machining result

2018 ◽  
Vol 108 (10) ◽  
pp. 736-742
Author(s):  
J. Hartig ◽  
B. Kirsch ◽  
J. Aurich
Keyword(s):  
Tungsten Carbide ◽  
Tool Life ◽  
Wear Mechanism ◽  
Ductile Iron ◽  
Cutting Edge ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Machining Performance ◽  
Edge Geometry ◽  
Homogeneous Preparation

Mit Schneidkantenpräparation kann das Werkzeug im Zerspanprozess an die Bearbeitungsaufgabe angepasst werden. Homogene Präparationen können dabei entweder auf hohe Belastungen des Werkzeugs oder ein optimiertes Bearbeitungsergebnis im Sinne der Oberfläche ausgelegt werden. In diesem Beitrag wurden die Schneidkanten von Hartmetall-Wendeschneidplatten unterschiedlich inhomogen präpariert, um den unterschiedlichen Anforderungen entlang des Eingriffs Rechnung zu tragen. Neben der Werkzeugstandzeit wurde das Prozessergebnis beim Außenlängs-Runddrehen von ausferritischem Gusseisen (ADI) 900 untersucht.   The preparation of cutting edges allows for tools to be tailored to the machining process. A homogeneous preparation can either be designed for high loads in the machining process or an optimized machining result on the surface. In this article, the cutting edges of tungsten carbide indexable inserts were prepared inhomogeneously and thus individually matched to the machining task. Tool life and machining performance while turning austempered ductile iron (ADI) 900 were investigated.

Kantenpräparation durch Formschleifprozesse*/Cutting edge preparation by form grinding

2017 ◽  
Vol 107 (06) ◽  
pp. 453-460
Author(s):  
E. Prof. Uhlmann ◽  
J. Bruckhoff
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Grinding Processes ◽  
Form Grinding ◽  
Cutting Edge Preparation ◽  
Edge Preparation

Angesichts steigender Anforderungen an Zerspanwerkzeuge nimmt die Schneidkantenpräparation einen immer größer werdenden Stellenwert ein, da sich so die Standzeit von Zerspanwerkzeugen erhöhen lässt. Die bisher eingesetzten Präparationsverfahren eignen sich meist nur für einfache Verrundungen an der Schneidkante. In umfangreichen Untersuchungen wurde die Eignung von Formschleifprozessen zur Herstellung definierter Schneidkantenmikrogeometrien anhand von Arbeitsergebnissen analysiert.   Due to increasing demands on cutting tools cutting edge preparation has a high priority because it influences the tool life. Current cutting edge preparation processes can only generate simple roundings on the cutting edge. By extensive investigations the suitability of form grinding processes for the production of defined microgeometries on the cutting edge was analysed.

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.

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