Correlation between Cutting Forces and Tool Wear in High Speed Milling of Graphite

2009 ◽  
Vol 69-70 ◽  
pp. 403-407 ◽  
Author(s):  
Li Zhou ◽  
Cheng Yong Wang ◽  
Xiao Jun Wang ◽  
Zhe Qin
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Tools ◽  
Dynamic Force ◽  
High Speed Milling ◽  
Time Frequency ◽  
Abrasive Friction ◽  
Force Components

Cutting tools suffer severe abrasive friction and wear in high speed milling of graphite. Cutting forces were measured and analyzed using time-frequency analysis method to reveal the correlation between cutting force variations and tool wear evolution. The static and dynamic force components increased prominently with tool wear. The cutting force Fy was found the most sensitive to the tool wear evolution. The waveform of cutting force became periodic and irregular with the increase of tool wear. Good correlation was found between the first force harmonic and tool wear.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Cutting Performance of Diamond Coated, TiAlN Coated and Carbide Cutting Tools in High Speed Milling Graphite

2014 ◽  
Vol 800-801 ◽  
pp. 451-459
Author(s):  
Yu Hai Zhou ◽  
Cheng Yong Wang ◽  
Qi Ming Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Orthogonal Experiment ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

This paper focusing on cutting performance high speed milling Electrical Discharging Machining (EDM) graphite with diamond coated、Carbide (WC) and TiAlN coated cutting Tools. tools wear, cutting force and machined surface had been researched. Experiment study including cutting speed, feed rate per tooth, radial depth of cut, axial depth of cut, and material of tools factors effects on the cutting forces. Cutting parameters are optimized based on the orthogonal experiment. Experiment in high speed milling with diamond coated tools all comparison with TiAlN coated and Carbide (WC) tools. On the surface quality, cutting forces and tool wear influence graphite cutting tool materials research, process parameters, tool design and optimization of processing parameters to provide supportive data. The minimum cutting force as the goal, through the orthogonal experiment for the optimization of cutting parameters obtained for the high speed milling graphite with diamond-coated tool: cutting force 360m/min,feed per tooth 0.15mm/z, radial depth of cut 0.9mm, axial depth of 9mm.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

Cutting force, tool wear and surface roughness in high-speed milling of high-strength steel with coated tools

2019 ◽  
Vol 33 (11) ◽  
pp. 5393-5398 ◽  
Author(s):  
Yuan Li ◽  
Guangming Zheng ◽  
Xu Zhang ◽  
Xiang Cheng ◽  
Xianhai Yang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
High Strength Steel ◽  
High Speed ◽  
High Strength ◽  
High Speed Milling ◽  
Coated Tools

Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface

2017 ◽  
Vol 233 (1) ◽  
pp. 18-30 ◽  
Author(s):  
Jian-wei Ma ◽  
Zhen-yuan Jia ◽  
Guang-zhi He ◽  
Zhen Liu ◽  
Xiao-xuan Zhao ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Tool ◽  
Helix Angle ◽  
Curved Surface ◽  
Geometrical Parameters ◽  
High Speed Milling

High-speed machining provides an efficient approach for machining Inconel 718 with high quality and high efficiency. For high-speed milling of Inconel 718 curved surface, the geometrical characteristics are changing continuously leading to a sharp fluctuation of cutting force, which will aggravate the tool wear. As the wear mechanism of coated cutting tool is seriously affected by the cutting tool geometrical parameters, suitable geometrical parameters of cutting tool should be selected to avoid the cutting tool from being worn out very quickly. In this study, the influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface is investigated with coated cutting tool, and the cutting force in milling process is also analyzed. The results show that the cutting force variation can manifest the tool wear degree, and the failure type of coated cutting tool in plane milling and curved surface milling after the same cutting length is different. Furthermore, the cutting tool geometrical parameters seriously affect the tool wear and the tool life in high-speed milling of Inconel 718 curved surface. Concretely, the small rake angle has greater strength and has superiority, the relief angle increasing can enhance the tool life, and the tool life is decreased with the increasing of helix angle for the cutting tool, whose helix angle is larger than 30°. This study provides a theoretical basis for cutting tool wear mechanism and cutting tool geometrical parameter selection in high-speed milling of Inconel 718 curved surface, so as to guarantee the machining efficiency in high-speed milling of Inconel 718 curved surface.

Research on the Influence of Tool Wear on Cutting Performance in High-Speed Milling of Difficult-to-Cut Materials

2016 ◽  
Vol 693 ◽  
pp. 1129-1134
Author(s):  
Zhao Ju Zhu ◽  
Jie Sun ◽  
Lai Xiao Lu
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Performance ◽  
High Speed Milling ◽  
Variation Trend ◽  
Cutting Tool Wear ◽  
Cutting Vibration

A series of research on the interactions among tool wear, cutting force and cutting vibration were conducted through high speed milling experiment in this paper, which objected the titanium alloy as difficult-to-cut materials. The results showed that the increasing of tool wear led to enlarging the cutting force and cutting vibration; and vice versa, the increasing of cutting force and cutting vibration aggravated the tool wear in the process of machining. Besides, the variation trend of tool wear with cutting was similar to the trend of cutting force, while the variation trend between cutting vibration and tool wear was different. Especially in the sharply cutting tool wear stage, the influence of tool wear on cutting vibration became more complicated.

An Experimental Study on Cutting Forces in the Threading and the Side Cut Turning With Coated and Uncoated Grades

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Firat Kafkas
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Dynamic Force ◽  
Low Alloy Steels ◽  
Workpiece Material ◽  
Cutting Force Components ◽  
Force Components

The objective of this study is to obtain the cutting force components on the threading insert. The cutting force data used in the analysis are measured by a three-dimensional dynamic force dynamometer. The AISI 4140 and AISI 4340 low alloy steels are selected for the experiment on the threading and the side cut turning. The inserts used for testing is the TiAlN coated and uncoated grades. LT22NR35ISO type insert is used in the experiment. During the experiments, no cutting fluid and a constant spindle speed is used. The thread pitch and the depth of cut were kept fixed at 3.5 mm and 0.05 mm for the radial feed per pass, respectively. The study emphasizes on the effects on the workpiece material and the cutting tool grade of the cutting force components that occur during the threading. Also, these results are compared with the findings that are obtained during the side cut turning. It is determined that the measured primary cutting and radial forces during the threading are approximately three times bigger than those during the side cut turning, although feed forces during the threading are approximately 30 times lower compared with the side cut turning. The TiAlN coated WC/Co grade shows the best performance with respect to the cutting force components. The specific cutting forces are determined in order to understand the interference of chips that occur during the threading. With the increase in the cumulative radial feed, the corresponding specific cutting forces become higher. It is reasoned that the difference in the specific cutting forces results from the alteration of the interference of the flowing chips. The specific cutting forces decrease in the beginning of the threading and then increases with the cumulative radial feed. The results show that the interference of the chip flow influences the threading force components to a very large extent.

Tool Wear and Surface Integrity in High Speed Milling of a Near Alpha Titanium Alloy

2006 ◽  
Vol 532-533 ◽  
pp. 644-647
Author(s):  
Yi Ping Zhang ◽  
Jiu Hua Xu ◽  
Guo Sheng Geng
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Milling ◽  
Good Surface ◽  
Alpha Titanium ◽  
Series Of Experiments

Ti-6.5Al-2Zr-1Mo-1V is a near alpha titanium alloy strengthened by solid solution with Al and other components. In this study, a series of experiments on tool wear and surface integrity in high speed milling (HSM) of this alloy were carried out. The tool lives under different cutting speeds were studied and the corresponding empirical equation of tool life was derived. Additionally, the wear mechanism of cutting tools was also discussed. Finally, surface integrity, including surface roughness, metallograph, work hardening and residual stresses, were examined and analysed. The result shows that good surface quality of workpiece could be obtained in HSM of the alloy.

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