Tool-Life of Wiper and Standard Cutting Tool in Finish Turning of SAE 4140

2013 ◽  
Vol 845 ◽  
pp. 760-764
Author(s):  
André J. Souza ◽  
Guilherme Cortelini Rosa
Keyword(s):  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Tool ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Technological Advancement ◽  
Nose Radius ◽  
Machined Surface ◽  
Finish Turning

Vibration tendency can rise in turning process when selecting a cutting tool with larger nose radius and/or increasing the feed rate. As consequence, it may affect the process performance by reducing the tool-life and causing damage to the machined surface finish. Moreover, the generated surface roughness strongly depends on the relation between feed rate and cutting tool nose radius. The wiper cutting tool is a recent technological advancement which is claimed to allow both the feed rate and the depth of cut to be doubled while maintaining the same surface finish value in comparison with standard tools. Thus, the objective of this paper is to benchmark tool-life of standard and wiper cutting tools in dry finish turning of SAE 4140 steel. The analysis consists of successive measurements of workpiece roughness and tool corner wear after each turning pass while using combined machining parameters for a target roughness average value close to 2 μm with both inserts being used under the manufacturers recommended cutting conditions. It is noted that the two inserts presented good performance both in the workpiece finish and in tool-wear.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

Tool wear and resulting surface finish during micro slot milling of polycarbonates using uncoated and coated carbide tools

2019 ◽  
Vol 234 (1-2) ◽  
pp. 52-65 ◽  
Author(s):  
Muhammad Pervej Jahan ◽  
Jianfeng Ma ◽  
Craig Hanson ◽  
Greg K Arbuckle
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Feed Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Slot Milling ◽  
Coated Tools ◽  
Tool Coating ◽  
Micro Channels

A growing application of polycarbonates is in the microfluidic disks and DNA detection devices, where surface finish of the micro-channels plays an important role. This study intends to investigate the tool wear and surface finish generated during micro slot milling of polycarbonate using uncoated, TiN-coated, and TiAlN-coated tungsten carbide tools. The effects of tool coating and the machining parameters on the possible reduction of tool wear and improvement of surface finish were investigated. It was found that with careful selection of cutting parameters and tool coating, micro-channels with smoother surface finish, minimum burrs around the edges, and controlled tool wear can be obtained using micro-milling. A combination of medium range of depth of cut and feed rate was found to improve the surface finish in polycarbonates, as well as minimize the tool wear. The TiAlN tool coating was found to only be effective in reducing tool wear without much effect on the machined surface. The adhesion was found to be the most dominating tool wear mechanism in uncoated carbide tool, followed by cutting edge chipping and tool nose’s plastic failure. The adhesion wear was found to be reduced in coated tools, especially in TiAlN-coated tools, although delamination wear started to dominate in the coated tools when higher feed rate and depth of cut were used. Both lower and higher of depths of cut were found to generate higher tool wear and leave traces of tool marks on the machined surface.

scholarly journals Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

2019 ◽  
Vol 9 (2) ◽  
pp. 109-113
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Aluminum Alloy 7075

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Multi Objective Optimization of Cutting Parameters in Machining Cellulose Based Hybrid Composites

2015 ◽  
Vol 761 ◽  
pp. 287-292
Author(s):  
Raja Izamshah ◽  
Zainudin Zuraidah ◽  
Mohd Shahir Kasim ◽  
M. Hadzley ◽  
M. Amran
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Multi Objective Optimization ◽  
Machining Performance ◽  
Machined Surface ◽  
Multi Objective ◽  
Optimization Of Cutting Parameters

Cellulose based hybrid composites are gaining popularity in the growing green communities. With extensive studies and increasing applications for future advancement, the need for an accurate and reliable guidance in machining this type of composites has increased enormously. Smooth and defect free machined surface are always the ultimate objectives. The present work deals with the study of machining parameters (i.e. spindle speed, feed rate and depth of cut) and their effects on machining performance (i.e. surface roughness and delamination) to establish an optimized setup of machining parameters in achieving multi objective machining performance. Cellulose based hybrid composites consist of jute (a bast fiber) and glass fiber embedded in polyester resins. Response Surface Methodology (RSM) using Box-Behnken Design (BBD) was chosen as the design of experiment approach for this study. Based on that experimental approach, 17 experimental runs were conducted. Mathematical model for each response was developed based on the experimental data. Adequacy of the models were analyzed statistically using Analysis of Variance (ANOVA) in determining the significant input variables and possible interactions. The multi objective optimization was performed through numerical optimization, and the predicted results were validated. The agreement between the experimental and selected solution was found to be strong, between 95% to 96%, thus validating the solution as the optimal machining condition. The findings suggest that feed rate was the main factor affecting surface roughness and delamination .

FRACTAL-BASED ANALYSIS OF THE EFFECT OF MACHINING PARAMETERS ON SURFACE FINISH OF WORKPIECE IN TURNING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (04) ◽  
pp. 1950043 ◽  
Author(s):  
GEEVIN JITHMAL PATHIRANAGAMA ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Quality ◽  
Surface Finish ◽  
Feed Rate ◽  
Fractal Theory ◽  
Complex Structure ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Cutting Depth ◽  
Machined Surface ◽  
Turning Operation

Analysis of workpiece surface quality is one of the major issues in manufacturing engineering. Turning operation is a famous machining operation that is widely used in machining of materials. In this research, we investigate the surface finish of machined workpiece from turning operation. For this purpose, we employ fractal theory to study the complex structure of machined workpiece’s surface in different conditions. The applied parameters include the variations of cutting depth, feed rate and spindle speed in wet and dry machining conditions. Based on the obtained results, we found the correlation between the increment of fractal dimension of machined surface and the increment of cutting depth, feed rate and spindle speed in wet machining condition. The obtained results will be discussed in relation with the complexity of machined surface. The employed method of analysis in this research can be widely applied to the analysis of the effect of different machining parameters and conditions on the surface quality of machined workpiece in case of different machining operations.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

scholarly journals An Investigation on Effect of Depth of Cut, Feed Rate and Tool Nose Radius on Induced Vibration and Surface Roughness during Hard Turning of 41Cr4 Alloy Steel Using Response Surface Methodology

2016 ◽  
Vol 7 ◽  
pp. 32-46
Author(s):  
Christopher Okechukwu Izelu ◽  
Samuel Chike Eze
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Depth Of Cut ◽  
Work Piece ◽  
Dominant Effect ◽  
Nose Radius ◽  
Tool Nose Radius

This paper describes an aspect of a set of turning experiments performed in attempt to model, predict and optimize the machining induced vibration and surface roughness as functions of the machining, tool and work-piece variables during hard turning of 41Cr4 alloy special steel, with standard cutting tool, on a conventional lathe. Amongst others, the input variables of interest include the depth of cut, feed rate and tool nose radius. The response surface methodology, based on central composite design of experiment, was adopted, with analysis performed in Design Expert 9 software environment. Quadratic regression models were suggested, and proved significant by an analysis of variance, for the machining induced vibration of the cutting tool and surface roughness of the work-piece. They also have capability of being used for prediction within limits. Analysis of variance also showed the depth of cut, feed rate and tool nose radius have significant effect on the machining induced vibration and surface roughness. Whereas the depth of cut has dominant effect on the machining induced vibration, the tool nose radius has dominant effect on the surface roughness. The optimum setting of the depth of cut of 1.33095 mm, feed rate of 0.168695 mm/rev, and the tool nose radius of 1.71718 mm is required to minimize the machining induced vibration at 0.08 mm/s2 and surface roughness at 6.056 μmm with a desirability of 0.830.

Optimization of Machining Parameters for CNC Turning of Different Materials

2014 ◽  
Vol 592-594 ◽  
pp. 605-609
Author(s):  
Surendra Kumar Saini ◽  
Sharad Kumar Pradhan
Keyword(s):  
Feed Rate ◽  
316L Stainless Steel ◽  
Cutting Tool ◽  
Fractional Factorial Design ◽  
Spindle Speed ◽  
Fractional Factorial ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Cnc Turning

Abstract. This paper proposes an experimental investigation of the most influencing machining parameters like spindle speed, feed rate and depth of cut on CNC turning of three metals viz. 316L Stainless steel, EN24 alloy steel and Ti 6 Al 4V alloy. Fractional factorial design with orthogonal array [L9 (33)] is employed for the optimization of these turning process parameters. All experiments were carried out using EMCO CNC 250 Turn machine with carbide cutting tool. The comparison revealed that feed rate and depth of cut are the most significant turning factors on surface roughness followed by spindle speed for these three metals.

DECODING OF THE RELATIONSHIP BETWEEN COMPLEX STRUCTURES OF MACHINED SURFACE AND TOOL WEAR IN MILLING OPERATION

Fractals ◽  
2020 ◽  
Vol 28 (07) ◽  
pp. 2050104
Author(s):  
MUHAMMAD OWAIS QADRI ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Fractal Dimension ◽  
Tool Wear ◽  
Surface Finish ◽  
Fractal Analysis ◽  
Complex Structure ◽  
Depth Of Cut ◽  
Complex Structures ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machining Operations

Surface finish of machined workpiece is one of the factors to evaluate the performance of machining operations. There are different factors such as machining parameters that affect the surface finish of machined workpiece. Tool wear is an unwanted machining issue that highly affects the surface finish of machined workpiece. In a similar way, different parameters (e.g. cutting speed, feed rate and depth of cut) also affect tool wear. In this research, we investigated how the complex structure of machined workpiece is related to the complex structure of tool wear. For this purpose, we benefited from the fractal analysis. The experiments were conducted based on the variations of machining parameters (depth of cut, feed rate and spindle speed), and accordingly the fractal dimension of machined surface was analyzed versus the fractal dimension of tool wear. Based on the obtained results, the complexity of machined surface is related to the complexity of tool wear. Fractal analysis could be applied to other machining operations to analyze the complex structures of machined surface and tool and potentially make a relationship between them.

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