Improving the Efficiency of the Cutting Tools Made of Mixed Ceramics by Applying Modifying Nanoscale Multilayered Coatings

2013 ◽  
Vol 712-715 ◽  
pp. 391-394 ◽  
Author(s):  
Anatoly S. Vereschaka ◽  
Sergey Nikolaevich Grigoriev ◽  
Ekaterina S. Sotova ◽  
Alexey Anatolevich Vereschaka
Keyword(s):  
Wear Resistance ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Ceramic Tool ◽  
Multilayered Coatings ◽  
Layered Coatings ◽  
Mixed Ceramics ◽  
Hardened Tool Steel ◽  
Mixed Ceramic ◽  
Influence Of Properties

The paper studies the influence of properties of a tool made of mixed ceramic by applying modifying with nanoscale multi-layered coatings on machinability of hardened tool steel XVG. The paper also examines the influence of cutting speed on wear resistance of mixed ceramic with nanoscale multilayered coatings. The mathematical models that found out the dependence of tool life of a ceramic tool with coating from cutting speed were developed.

Cutting Performance and Wear Mechanism of Si3N4-Based Nanocomposite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 324-329 ◽  
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Jin Peng Song
Keyword(s):  
Wear Resistance ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Tool Materials ◽  
High Cutting Speed ◽  
The Matrix

Si3N4/TiN nanocomposite tool and Si3N4/Ti(C7N3) nanocomposite tool were prepared. The cutting performance and wear mechanism of Si3N4-based nanocomposite ceramic tool was investigated by comparison with a commercial sialon ceramic tool in machining of 45 steel. Si3N4-based nanocomposite ceramic tool exhibits the better wear resistance than sialon at the relatively high cutting speed. The increased cutting performance of Si3N4-based nanocomposite ceramic tool is ascribed to the higher mechanical properties. Nano-particles can refine the matrix grains and improve the bonding strength among the matrix grains of Si3N4-based nanocomposite ceramic tool materials. It contributes to an improved wear resistance of the cutting tools during machining.

Improving Tool Wear Resistance in Inconel 718 Cutting by Considering Surface Microstructures of CBN Cutting Tool

2016 ◽  
Vol 1136 ◽  
pp. 561-566
Author(s):  
Tatsuya Sugihara ◽  
Shota Takemura ◽  
Toshiyuki Enomoto
Keyword(s):  
Wear Resistance ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Polished Surface ◽  
Rake Face ◽  
Crater Wear ◽  
Surface Microstructures

Nickel-based superalloys such as Inconel 718 are known as one of the most difficult-to-cut materials due to their mechanical and chemical properties and the tool life is extremely short. Recently, Cubic-Boron-Nitride (CBN) has received a considerable attention as a material for cutting tools and has been considered to be a major candidate for high performance cutting of Inconel 718. However, the detailed wear behavior of CBN tools in cutting of Inconel 718 is not sufficiently understood yet, and the performances of CBN tools are still insufficient in practical use. To overcome this problem, we first conducted orthogonal cutting experiments on Inconel 718 at low (20 m/min) and high (100 m/min) cutting speeds employing CBN cutting tools to clarify the detailed wear mechanisms. Moreover, relationship between surface microstructures of the cutting tool and wear resistance was investigated. As a result, it was found that a rake face with micro grooves significantly suppressed the crater wear at low cutting speed, although polished surface rake face reduced the initial crater wear by approximately 40 % compared to the non-polished tool in high speed cutting of Inconel 718.

scholarly journals Development of Surface Roughness in Hard Turning of 100Cr6 Using Mixed Ceramic Cutting Tool with Wiper Geometry and Conventional Geometry

2013 ◽  
Vol 21 (Special-Issue) ◽  
pp. 193-198
Author(s):  
Michaela Samardžiová ◽  
Miroslav Neslušan
Keyword(s):  
Surface Roughness ◽  
Hard Turning ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Hard Machining ◽  
Roughness Parameters ◽  
Ceramic Tool ◽  
Mixed Ceramic

Abstract Hard turning has been applied in machining since the early 1980s. There is an effort to substitute finish grinding by hard machining, because of machining by cutting tool with defined geometry. For machining of hardened steels (up to 45 HRC) are used two different cutting materials. PCBN are used the most for discontinuous machining of hardened steel (up to 63 HRC) and mixed ceramic tools, which are used in the experiment. This paper reports a development of surface roughness parameters when using wiper tool geometry of mixed ceramic tool and conventional geometry of mixed ceramic tool in hard turning. Roughness parameters (Ra, Rz, Rsk, Rku, RSm, Rdq) are measured when changing the feed, depth of cut and cutting speed are constant.

Examining the machinability of 38MnVS6 microalloyed steel, cooled in different mediums after hot forging with the coated carbide and ceramic tool

2021 ◽  
pp. 095440622098449
Author(s):  
Barış Özlü ◽  
Halil Demir ◽  
Mustafa Türkmen ◽  
Süleyman Gündüz
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Microalloyed Steel ◽  
Cutting Tools ◽  
Experimental Studies ◽  
Hot Forging ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Coated Carbide

In this study, the effect of the microstructure, hardness, and cutting speed on main cutting force and surface roughness in medium carbon microalloyed steel cooled in different mediums after hot forging, was investigated. As-received sample, which was not hot forged, and the samples cooled in the sand, air, oil, and polymerized water after hot forging were used for the experimental studies. The machinability tests were performed via turning method by using coated carbide and coated ceramic cutting tools with five cutting speed (120, 150, 180, 210, and 240 m/min), constant feed rate (0.04 mm/rev), and constant depth of cut (0.6 mm). The microstructure examinations of the samples were carried out and their hardness values were determined. Also, the wear of cutting tools were examined with scanning electron microscope. In the experimental study, it was revealed that the microstructure, hardness and cutting speed had a significant effect on the surface roughness values of the samples cooled in dissimilar environments following forging. Moreover, the samples cooled in air and polymerized water, whose hardness increased depending on the increase in the cooling rate, had the highest cutting force after machining by using the coated carbide and ceramic tool.

Effect of Tool Wear on Tool Life and Surface Finish when Machining DF-3 Hardened Tool Steel

2013 ◽  
Vol 315 ◽  
pp. 241-245 ◽  
Author(s):  
Ali Davoudinejad ◽  
M.Y. Noordin ◽  
Danial Ghodsiyeh ◽  
Sina Alizadeh Ashrafi ◽  
Mohsen Marani Barzani
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Tool Steel ◽  
Wear Mechanism ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Mixed Ceramic

Hard turning is a dominant machining operation performed on hardened materials using single-point cutting tools. In recent years, hard turning operation has become more and more capable with respect to various machinability criteria. This work deals with machinability of hardened DF-3 tool steel with 55 ±1 HRC hardness at various cutting conditions in terms of tool life, tool wear mechanism and surface roughness. Continuous dry turning tests were carried out using coated, mixed ceramic insert with honed edge geometry. Two different cutting speeds, 100 and 210 m/min, and feed rate values of 0.05, 0.125 and 0.2 mm/rev were used with a 0.2 mm constant depth of cut for all tests. Additionally scanning electron microscope (SEM) was employed to clarify the different types of wear. As far as tool life was concerned, best result was achieved at lowest cutting condition whereas surface roughness values decreased when operating at higher cutting speed and lower feed rate. Additionally maximum volume of material removed is obtained at low cutting speed and high feed rate. Dominant wear mechanism observed during the experiments were flank and crater wear which is mainly caused by abrasive action of the hard workpiece material with the ceramic cutting tools.

scholarly journals Alternative Binder Carbide Tools for Machining Superalloys

2008 ◽  
Author(s):  
Daniel Waldorf ◽  
Scott Liu ◽  
Michael Stender ◽  
Daniel Norgan
Keyword(s):  
Wear Resistance ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
New Class ◽  
Nickel Based Superalloy ◽  
Composite Tool ◽  
Binder Composition ◽  
Positive Effect ◽  
Cutting Speeds

This study examines the performance of a new class of wear-resistant but economical cutting tools produced by varying the binder composition of standard cemented carbide composites. By replacing some or all of the cobalt binder with rhenium and nickel-based superalloy, a stronger composite tool results, potentially capable of machining heat-resistant superalloys at significantly higher cutting speeds. Sample tools with alternative binder were produced and compared to standard tools bound with cobalt only. Turning experiments on Inconel 718 were run to evaluate wear resistance and tool life for several grades. The experimentation also examined the effects of varying the relative proportions of each binder constituent as well as the overall binder percentage in the composite. Results show a clear advantage of the alternative binder tools as evidenced by a 150% increase in tool life or the equivalent of an 18% increase in cutting speed. Although increasing amounts of rhenium in the binder show a positive effect on performance, the effects of superalloy and overall binder % are inconclusive.

Heat Cutting for Remanufacture Hardness Deposited Materials

2011 ◽  
Vol 101-102 ◽  
pp. 978-981
Author(s):  
Zhi Yuan Wu ◽  
Xiao Jun Shi ◽  
Xin Li Tian ◽  
Xiu Jian Tang ◽  
Shu Zhang
Keyword(s):  
Heating Temperature ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Test Results ◽  
Ceramic Tool ◽  
Cutting Depth ◽  
Si3n4 Ceramic ◽  
Importance Factor ◽  
Red Hardness ◽  
Better Than

Three cutting tools, YG610, Si3N4 ceramic tool and CBN were adopted for heat cutting deposited materials. The test results show that though the impacts to the tools reducing, the CBN still break seriously. The condition by Si3N4 ceramic tool is better than CBN, whose types of tool failure change from breakage to wear. The YG610 is best material for heat cutting, whose minimum VB value is only 0.3mm. In the experiment, the wear increase with the increasing of heating temperature, cutting speed, cutting depth. But it decreased with feed rate. The analysis results show that the red-hardness is most importance factor for wears of YG610.

scholarly journals Comparison on various machinability aspects between mixed and reinforced ceramics when machining hardened steels

2019 ◽  
Vol 20 (1) ◽  
pp. 109 ◽  
Author(s):  
Hamdi Aouici ◽  
Mohamed Elbah ◽  
Asma Benkhelladi ◽  
Brahim Fnides ◽  
Lakhdar Boulanouar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Specific Cutting Force ◽  
Industrial Sectors ◽  
Mixed Ceramic ◽  
Ceramic Insert

The hard turning process has an attracting interest in different industrial sectors for finishing operations of hard materials. However, it still presents disadvantages with respect to process capability and reliability. This paper describes a comparison of surface roughness, specific cutting force and flank wear between mixed ceramic CC650 (Al2O3 (70%) + TiC (30%)) and reinforced ceramic CC670 (Al2O3 (75%) + SiC (25%)) cutting tools when machining in dry hard turning of AISI 4140, treated at 52 HRC using the response surface methodology (RSM). A mathematical prediction model of the machining responses has been developed in terms of cutting speed, feed rate and cutting time parameters. Experimental observations show that the surface roughness obtained with the mixed ceramic insert significantly improved when compared with reinforced ceramic insert with a ratio of 1.44. In the same way, insert CC650 has better performance compared to reinforced ceramic inserts CC670, in terms of the specific cutting force and flank wear.

SURFACE ROUGHNESS AND CUTTING FORCES IN TURNING OF TOOL STEEL WITH MIXED CERAMIC AND CUBIC BORON NITRIDE CUTTING TOOLS

2015 ◽  
Vol 39 (2) ◽  
pp. 323-336 ◽  
Author(s):  
Bekir Yalçın
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tool Steel ◽  
Cutting Forces ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Ceramic Tool ◽  
Machining Processes ◽  
Ceramic Tools ◽  
Mixed Ceramic

Tool steel has been widely used, especially to manufacture forming dies and molds by machining processes. Generally, cubic boron nitride (CBN) and ceramic tools are recommended for finish machining a specific steel. This study contributes to filling the research gap for the selection of low- content CBN tools or mixed ceramic tools for turning of hard tool steel. The turning tests were conducted to determine the performance of CBN and the mixed ceramic tools in turning soft (HRC22) and hard (HRC52) H13 tool steel with different cutting speeds, feed rates and depths of cut. ANOVA was used to determine the interaction of the cutting parameters on the surface roughness and cutting forces obtained from turning tests. The results indicate that the surface roughness in hard turning was lower with the CBN tool than with the ceramic tool. On the other hand, the cutting forces in turning with the ceramic tool were lower. Acceptable regular chip formation increases with the cutting speed for each tool.

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