Experimental Study on the Thread Turning Performance of Two TiAlN Coated Thread Inserts with Different Features

2013 ◽  
Vol 797 ◽  
pp. 149-154
Author(s):  
Kang Li ◽  
Peng Nan Li ◽  
Ming Chen
Keyword(s):  
Experimental Study ◽  
Tool Wear ◽  
Coating Thickness ◽  
Matrix Material ◽  
Chip Morphology ◽  
Rake Face ◽  
Type Alloy ◽  
Alloy Matrix ◽  
Coating Technology ◽  
Coated Tools

With the development of the coating technology, coated tools have been widely used in processing industries. Thread turning is one of its applications. The performance of coated thread inserts varies with the change of coating material, coating thickness, matrix material and tool structure. Two tungsten-cobalt type alloy matrix, TiAlN coated thread inserts with different coating thickness, rake face type had been employed to conduct the thread turning experiments. By analyzing the cutting forces, chip formation and tool wear, it was found that insert with coating thickness of 4.35 μm would result in less tool wear under MQL condition, smaller cutting force, better chip morphology under dry condition compared with insert with coating thickness of 2.38 μm.

scholarly journals Effect of Volcano-like Textured Coated Tools on Machining of Ti6Al4V: An Experimental and Simulative Investigation

2021 ◽  
Author(s):  
Yun Zhou ◽  
Yonghong Fu ◽  
Jie Yang
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Material Model ◽  
Ti6al4v Alloy ◽  
Cutting Conditions ◽  
Vacuum Arc ◽  
Rake Face ◽  
Coated Tools ◽  
Coated Tool

Abstract In this work, the main aim is to reduce the adhesion and wear that happened during machining of the Ti6Al4V alloy by employing volcano-like texture on the rake face of coated tool. A combination of experimental and simulative investigation was adopted. DEFORM-3D software with updated Lagrangian formulation was used for numerical simulation, and the thermo-mechanical analysis was performed using Johnson-Cook material model to predict the cutting temperature, cutting forces, chip morphology and tool wear. In cutting experiments, volcano-like textures with different area densities (10%, 20%, 30%) were fabricated by fiber laser on the rake face of cemented carbide tools close to the main cutting edge. Then, these textured tools were deposited with CrAlN coating through cathodic vacuum arc ion plating technique. Experiments in cutting Ti6Al4V alloy were carried out with the textured coated tools and non-textured coated tool under dry and wet cutting conditions. Then, the chip morphology, chip size and tool wear were investigated. The results showed that textured coated tools were superior to conventional tool. Especially in wet cutting, compared with those of non-textured coated tool, the adhesion area and the chip curling radius of the coated tool with texture area density of 20% (VCT2) were reduced by 31.2% and 49.7%, respectively. Therefore, VCT2 tool showed a better cutting performance. Finally, the mechanisms of textured coated tools under dry and wet cutting conditions were proposed.

Investigation of Tool-Wear and Surface Roughness in Turning Ti6Al4V under Different Cooling Lubrication Conditions

2014 ◽  
Vol 800-801 ◽  
pp. 180-185 ◽  
Author(s):  
Teng Da Wang ◽  
Er Liang Liu ◽  
Zhen Li ◽  
Hong Yan Ju ◽  
Yong Chun Zheng
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Chip Morphology ◽  
Protective Role ◽  
Rake Face ◽  
Flank Face ◽  
Lubrication Conditions ◽  
Morphology Influence ◽  
Interaction Relationship

In titanium alloy machining, under different cooling lubrication conditions, the variation of tool wear and chip morphology have a certain effect on the surface roughness. Under different cooling lubrication conditions, in order to analyze the variation of tool wear, chip morphology and surface roughness, the surface roughness values are measured ​​and the variation in tool wear and chip morphology are observed, and then the interaction relationship between the tool wear and the chip morphology is analyzed. The results show that the tool wear and chip morphology influence on the surface roughness. Under different cooling lubrication, the rake face wear do not change significantly, but wet cooling and MQL play a protective role for the flank face wear.

Experimental Investigations to Evaluate the Performance of Alternate Striped Coated Carbide Inserts in Turning of AISI 1040 Steel

2015 ◽  
Author(s):  
L. V. R. S. V. Prasad Chilamkurti ◽  
Naga Lakshmi Pavani Puvvada ◽  
Ramji Koona ◽  
Venkata Ramana Swarna
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Single Layer ◽  
Cutting Edge ◽  
Experimental Investigations ◽  
Clear Understanding ◽  
Rake Face ◽  
Machining Conditions ◽  
Coated Tools ◽  
Coated Carbide

During machining in order to improve the performance of the tool, it is necessary to have a clear understanding of chip flow and chip-tool interactions on the rake face. The predominating factors which influence the performance of cutting tool are proper combinations of process variables, tool and workpiece. Focusing more on environmental and economic considerations, dry machining is preferred in the present work to study and evaluate the performance of the multi-striped alternate coated Tungsten Carbide (WC) inserts. Dry turning tests on AISI 1040 steel at various machining conditions have been carried out using uncoated and striped coated cutting tools to deliberate the wear patterns close to the cutting edge. An effective tool coating helps the tool manufacturers to increase the tool life during high speed machining conditions. In the earlier research, in evaluating the performance of single and multi-layer carbide tools, tool wear has been considerably reduced in multi-layer coated tools compared with single layer coated tools. In the current work, to further reduce the tool wear an attempt has been made to assess the tool wear with striped coated carbide tools having alternate bands of hard and soft coatings located close to the cutting edge. The findings are significant in the current study which shows that no crater wear has been observed. Further authors also tried for the optimum rake face utilization by having the proposed band of coatings close to the cutting edge.

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%.

A Review on Role of Aluminum Matrix Materials, Failure Causes and Optimization Techniques

2021 ◽  
Vol 6 (3) ◽  
pp. 1-11
Author(s):  
Tilahun Y ◽  
◽  
Mesfin G ◽  
Keyword(s):  
Failure Modes ◽  
Matrix Material ◽  
Aluminum Matrix ◽  
Ductile Failure ◽  
Failure Surface ◽  
Optimization Techniques ◽  
Alloy Matrix ◽  
Modes Of Failure ◽  
Causes Of Failure

Aluminum is a metal matrix material which is widely used in different industrial as well as engineering applications.it has a great advantage due to its remarkable properties like less density, formability, and light in weight, recyclability and other properties. but, failure of aluminum matrix materials are the main problems in aluminum industries now a days.in this review role of aluminum and its alloys as matrix materials, their failure modes, causes of failure and optimization techniques to minimize this failure modes and causes of failure are discussed. Sources are reviewed which are from 2005 to recent one. Consequently, most modes of failure, causes of failure and most optimization techniques of aluminum and its alloy matrix materials are found. most modes of failure are mechanical related like fatigue failure, surface cracking, ductile failure, porosity formation, and stress related like stress corrosion cracking, surface weakness due to repeated stresses and other factors are summarized.in causes of failure mostly like corrosion formation, wear formation and poor mechanical properties are discussed.

Study of the Effect of Tool Wear on Cutting Ti6Al4V Process

2013 ◽  
Vol 690-693 ◽  
pp. 2030-2035
Author(s):  
Shu Bao Yang ◽  
Hong Chao Ni ◽  
Guo Hui Zhu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Key Factors ◽  
Serrated Chip ◽  
Comprehensive Properties ◽  
Commercial Applications ◽  
On Chip ◽  
Rapid Tool

Ti6Al4V alloy is widely used in the aircraft industry, marine and the commercial applications due to its excellent comprehensive properties. However, its poor machinability prevents it from application widely, and the rapid tool wear is one of the key factors. The FEM models of cutting titanium alloy are established. The effect of tool wear on chip morphology, cutting temperature and cutting force are studied. The simulation results show that: the cutting force and cutting temperature will rise with the increase of tool wear. Furthermore, the degree of chip deformation will improve, but the frequency of serrated chip tooth occurred will decrease.

Physical and Mechanical Properties of Composites with Aluminum Alloy Matrix Designed for Metal Forming

2013 ◽  
Vol 212 ◽  
pp. 59-62 ◽  
Author(s):  
Jerzy Myalski ◽  
Jakub Wieczorek ◽  
Adam Płachta
Keyword(s):  
Mechanical Properties ◽  
Metal Forming ◽  
Matrix Material ◽  
Physical And Mechanical Properties ◽  
Mechanical Mixing ◽  
Alloy Matrix ◽  
Segregation Process ◽  
The Matrix ◽  
Glass Carbon ◽  
Properties Of Composites

The change of matrix and usage of the aluminum alloys designed for the metal forming in making the composite suspension allows to extend the processing possibility of this type of materials. The possibility of the metal forming of the composites obtained by mechanical mixing will extend the range of composite materials usage. Applying of the metal forming e.g. matrix forging, embossing, pressing or rolling, will allow to remove the incoherence of the structure created while casting and removing casting failures. In order to avoid the appearance of the casting failures the homogenization conditions need to be changed. Inserting the particles into the matrix influences on the shortening of the composite solidification. The type of the applied particles influenced the sedimentation process and reinforcement agglomeration in the structure of the composite. Opposite to the composites reinforced with one-phase particles applying the fasess mixture (glassy carbon and silicon carbide) triggered significant limitation in the segregation process while casting solidification. Inserting the particles into the AW-AlCu2SiMn matrix lowers the mechanical properties tension and impact value strength. The most beneficial mechanical properties were gained in case of heterofasess composites reinforced with the particle mixture of SiC and glass carbon. The chemical composition of the matrix material (AW-AlCu2SiMn) allows to increase additionally mechanical characteristics by the precipitation hardening reached through heat casting forming.

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