Development and Application of Coated Ceramic Cutting Tools

2006 ◽  
Vol 45 ◽  
pp. 1155-1162 ◽  
Author(s):  
E. Uhlmann ◽  
T. Hühns ◽  
S. Richarz ◽  
Walter Reimers ◽  
S. Grigoriev
Keyword(s):  
Cutting Tools ◽  
Substrate Material ◽  
Machining Process ◽  
Machining Processes ◽  
Ceramic Substrates ◽  
Pvd Coating ◽  
High Temperature Alloys ◽  
Pre Treatment ◽  
Process Measurements ◽  
Comprehensive Measurement

Ceramics are characterized by their special wear and temperature resistance. Thus, they are especially suited for the cutting of high-temperature alloys and difficult-to-cut materials. Due to their low ductility, they show brittle-hard properties during the process, which lead to a sudden failure of the tool. But it is possible to create composite materials that counteract the brittle-hard behavior of the substrate material by PVD-coating. The objective of the investigations is to increase the process stability of coated ceramic indexable inserts made of aluminum oxide and silicon nitride through the optimisation of the mechanical pre-treatment of the substrate materials. To this end, the ceramic substrates are pre-treated by different abrasive machining processes. Comprehensive measurement evaluations show the influence of the machining process and strategy on the formation of surface and subsurface. The workpieces ground and lapped in different ways are subsequently coated by an especially developed PVD process. Measurements show the influence of the pre-treatment on the surface structure and on the mechanical properties of the composite material. The application of the developed and manufactured tools in cutting tests verifies the results of the measurements.

scholarly journals A Scientific Approach of using the DMAIC Methodology to Investigate the Effect of Cutting Tool Life on Product Quality and Process Economics: A Case Study of a Saudi Manufacturing Plant

2021 ◽  
Vol 11 (1) ◽  
pp. 6799-6805
Author(s):  
A. B. E. Aichouni ◽  
H. Abdullah ◽  
F. Ramlie
Keyword(s):  
Process Improvement ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Machining Process ◽  
Real Field ◽  
Manufacturing Plant ◽  
Manufacturing Companies ◽  
Machining Processes ◽  
Process Economics

One of the major priorities for manufacturing companies in the globalized economy is the ability to offer high-quality products to customers at the lowest production cost. Globally, process improvement methods and techniques are used to reduce waste and improve product and service quality. This paper aims to propose a systematic model based on process improvement methodologies and tools to help the manufacturing companies decide on cutting tool life and other manufacturing issues. This research seeks to prove that some common industry practices, such as changing cutting tools in machining processes, can significantly affect the economics of production and the overall performance of the plant. The research is mainly based on analyzing real field data using the DMAIC methodology to identify improvements in order to achieve a balance between economy and quality in a Saudi manufacturing plant. Although the study was concerned only with changing cutting tools in the machining process in an air conditioning plant, its findings and conclusions can be generalized to all manufacturing processes.

Tool-Based Micro/Nano Machining: Development of Innovative Machine and Machining Processes

2020 ◽  
Author(s):  
Mustafizur Rahman ◽  
Keng Soon Woon ◽  
Wee Keong Neo
Keyword(s):  
Surface Finish ◽  
Continuous Production ◽  
Current Trend ◽  
Cutting Tools ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Successful Implementation ◽  
Micro Machining ◽  
Machining Processes ◽  
Ultra Precision

Abstract It is an unarguably fact is that the current trend in manufacturing is miniaturization of products with extreme surface finish. I addition, the surface finish and dimensional accuracy requirements of products as well components are getting remarkably stringent, especially in the areas of vision, information, biotech, environmental, measurement and medical industries. Moreover, these products need to accommodate increased number of functions. Production of such products and parts of micron level size with very high dimensional accuracy of nano meter level is getting more importance because of a steadily increasing demand for such industrial products. To satisfactorily meet these challenges micro/nanomachining technology must be developed. Such machining is usually performed either using techniques based on energy beams (beam-based micro-machining) or using solid cutting tools (tool-based micro/nanomachining). Some of the limitations of beam-based micro-machining are due to poor control of 3D structures, low aspect ratio of products and also low material removal rate. In addition, special facilities are required to perform these processes and the maximum achievable dimensions are relatively small. However, with the application of tool-based micro/nanomachining technology some of these limitations can be satisfactorily overcome using ultra precision machine tools and solid cutting tools to produce the micro-features with well-controlled shape, features and tolerances. In many cases, compound or hybrid or simultaneous machining process is required for effectively performing micromachining. To meet the challenges, multi-process machines are required and unfortunately such machines are not available. Consequently, the author will present the development of a first-of-its-kind multi-process machine tool and the innovative approaches to develop various compound, hybrid and simultaneous machining processes for the successful implementation of micromachining. Recently, nanomachining of difficult-to-machine materials is also getting more importance with the pervasive demand for fabrication of miniature, thinner and lighter products, intricate micro-shapes and structures on such materials. In addition, the products also require nano meter level surface finish. The author would like to present his contribution especially in the area ductile mode machining of brittle materials. This paper also presents the recent developments in the areas of deeper understanding of the mechanisms and machining technologies to generate nano-finish surface by machining processes. In this paper, the basic understanding of nanomachining mechanism, ‘extrusion-like’ chip formation metal cutting is briefly discussed. With the emergence of hybrid freeform surfaces to increase the optical performance and to provide new functions. To fulfill these objectives, the author and his team have carried out ultra-precision machining using fast tool servo (FTS) and slow slide servo (SSS) mechanisms. Some typical examples of the development of innovative nano machining processes and products have been presented in this paper. Finally, the development of a rotating tool for continuous production of radial Fresnel lenses has been presented.

Green Manufacturing - Textured Novel Cutting Tool for Sustainable Machining: A Review

2020 ◽  
Vol 899 ◽  
pp. 135-143
Author(s):  
Awais Farooqi ◽  
Nukman bin Yusoff
Keyword(s):  
Sustainable Manufacturing ◽  
Cutting Tools ◽  
Minimum Quantity Lubrication ◽  
Green Manufacturing ◽  
Machining Process ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Nano Fluid ◽  
Prime Objective ◽  
Removal Processes

Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

scholarly journals In-Process Chatter Detection Using Signal Analysis in Frequency and Time-Frequency Domain

Machines ◽  
2021 ◽  
Vol 10 (1) ◽  
pp. 24
Author(s):  
Michele Perrelli ◽  
Francesco Cosco ◽  
Francesco Gagliardi ◽  
Domenico Mundo
Keyword(s):  
Wavelet Packet ◽  
Cutting Tools ◽  
Poor Quality ◽  
Machining Process ◽  
Surface Finishing ◽  
Work Piece ◽  
Chatter Detection ◽  
Machining Processes ◽  
Time Frequency ◽  
Working Parameters

All machining processes involve vibrations generated by structural sources such as a machine’s moving parts or by the interaction between cutting tools and work-pieces. Relative vibrations between the work-pieces and the cutting tool are the most relevant from the point of view of the regenerative chatter phenomenon. In fact, these vibrations can lead to a chip yregeneration effect, which results in unwanted consequences, rapidly degenerating towards a very poor quality of surface finishing or, in case of severe chatter conditions, to machine-tool or work-piece damage. In the past decades, two different approaches for chatter avoidance were proposed by the scientific community, and they are commonly referred to as Out-of-Process (OuP) and in-Process (iP) solutions. The OuP solutions are off-line approaches, which allow to properly set the working parameters before machining starts. Ip solutions are on-line techniques, which allow to dynamically change the working parameters during machining by using single or multiple sensors. By monitoring the machining process, iP algorithms try to keep the machining process in stable working conditions while keeping high productivity levels. This study dealt with a novel iP chatter-detection strategy based on the Power Spectral Density (PSD) analysis and on the Wavelet Packet Decomposition (WPD) of different sensor signals. The preliminary results demonstrate the stability and feasibility of proposed indicators for chatter detection in industrial application.

Experimental Study of Laser Texturing Processes on the Lubricant Retention of Carbide (WC-Co) Surfaces

2019 ◽  
Vol 813 ◽  
pp. 55-61
Author(s):  
Juan Manuel Vázquez-Martínez ◽  
Irene Del Sol ◽  
Moises Batista ◽  
Severo Raúl Fernández-Vidal ◽  
Pedro M. Hernandez ◽  
...  
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Scanning Speed ◽  
Machining Process ◽  
Cutting Fluids ◽  
Laser Texturing ◽  
Machining Processes ◽  
Wide Range ◽  
Machined Parts ◽  
Cutting Processes

Machining process usually involves relevant wear effects on the cutting tool, producing undesirable surface features on the work-pieces. Lubricants and cooling fluids are used with the aim to minimize the wear phenomena as well as high temperatures produced during the cutting processes. However, the use of these fluids may have an adverse environmental impact. For this reason, the reduction of quantity of cutting fluids used in the machining process is a requirement in order to improve the performance and sustainability of the process. For this purpose, this work proposes an increase of the lubricant retention ability for cutting tools based on surface modification. In this research, micro-geometrical features of Carbide (WC-Co) surfaces have been modified by laser texturing techniques. A wide range of roughness topographies had been developed by changing the laser irradiation parameters of energy density of pulse (Ed) and scanning speed of the beam (Vs). Different geometries of the textured tracks (single spots, linear tracks, circular tracks) also were studied. Moreover, through specific roughness features conducted by texturing process, the retention ability of cutting fluids was modified. It was evaluated by the contact angle between liquid and solid phases. This modification allowed to increase the self-lubricant effect of the WC-Co surface. This methodology has been validated on carbide tools under lubricated machining processes. Wear effects on the cutting tool were reduced and the surface finish of the machined parts was remained at least in the same ranges as non-modified tools.

Energy Savings for Sustainability of Machining Process

2015 ◽  
Author(s):  
Ganesh Bharambe ◽  
Prakash Dabeer ◽  
Kumar Digambar Sapate ◽  
Suresh M. Sawant
Keyword(s):  
Energy Consumption ◽  
Material Handling ◽  
Metal Cutting ◽  
Energy Savings ◽  
Specific Energy Consumption ◽  
Cutting Tools ◽  
Machining Process ◽  
Cutting Fluid ◽  
Machining Processes ◽  
Set Up

Processing of metals in industries is lifeline of economy of country, which helps to shape the country. Energy saving in this process is attributed to both the parts ie process of machining and energy consumed in machine tools itself. The process of material removal had experienced lot of improvements in last few decades. This consists of developments in pre-machining processes, metal cutting methods and developments in cutting theories and cutting tools. Cutting fluid is one of challenging field to yield more favourable results. Manufacturing practices beyond its existing limits, process and machine automations, using the previous data for improving machinabilities, optimizing through relative benchmarks (a market driven schemes) shall lead the manufacturing speed to a new high. Adaptibility of manufacturing set up to absorb new requirement will also be a controlling factor for acceleration of manufacturing processes. This paper discusses the efforts to reduce the energy to produce a product. Various methods are discussed to minimize the energy consumed for driving the machine components such as spindle, feeding device, lubricating system, cutting fluid system, indexing and tooling management, speed and feed controlling devices etc. Different requirements such as friction energy in braking action, speed reducing or cushioning will also consume certain amount of energy during its operations. Therefore one has to understand the various types of energy flows and classification of energy forms used from place to place. Study of constructional features of machines brings a lot of opportunities for savings in energy. The concepts of material handling, fluid handling like hydraulic and pneumatic circuits, lubrication system, shall also provide the opportunities for savings in energy consumption. Energy used for working of accessories whether they are required at that particular moments needs to be considered from time to time. There are few more methods for locating the chances for arresting the energy wastages and reducing specific energy consumption referring a particular process or function. Previous data generated for similar functions can be referred for comparison and efforts can be added to reduce the requirement of energy. Efficient and effective utilization of equipment shall open a fresh path for finding the energy reductions. Sustainability of machining processes can be ensured for future using the lean energy utilizations for productions. Authors have explained the live cases to demonstrate reduction in energy consumption. Few potential guidelines are also narrated in this line. Further few cases are discussed from literature survey which support and will help to pursue the target.

scholarly journals IN-LINE SPATIAL MONITORING OF CUTTING TOOL-WEAR

2017 ◽  
Vol 44 (1) ◽  
pp. 41
Author(s):  
Luka Čerče ◽  
Davorin Kramar ◽  
Janez Kopac
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Machining Process ◽  
Strong Impact ◽  
Machining Processes ◽  
Cutting Tool Wear ◽  
Manual Inspection ◽  
Complete Automation

The tool-wear of cutting tools has a very strong impact on the product quality as well as efficiency of the machining processes. Despite the nowadays high automation level in machining industry, tool -wear diagnostic that is measured of the machine tool, still prevent complete automation of the entire machining process. Therefore, its in line characterization is crucial. Thus the paper presents developed innovative, robust and reliable direct measuring procedure for measuring spatial cutting tool-wear in-line, with the usage of laser profile sensor. The technique provides possibility for determination of 3D wear profiles, as advantage to currently used 2D subjective techniques (microscopes, etc.). The use of proposed measurement system removes the subjective manual inspection and minimizes the time used for wear easurement. In the manuscript the system is experimentally tested on a case s tudy, with further in-depth performed analyses of spatial cutting tool-wear.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Challenges and Issues in the Design of Micro-Machined Antennas - A Review

2020 ◽  
Vol 13 ◽  
Author(s):  
Ashish Kumar ◽  
Amar Partap Singh Pharwaha
Keyword(s):  
Patch Antenna ◽  
Ground Plane ◽  
Substrate Material ◽  
Review Article ◽  
High Index ◽  
Performance Characteristics ◽  
Machining Process ◽  
Patch Antennas ◽  
Micro Machining ◽  
The Impact

Background: Patch antennas are composed of the substrate material with patch and ground plane on the both sides of the substrate. The dimensions and performance characteristics of the antenna are highly influenced by the choice of the appropriate substrate depending upon the value of their dielectric constant. Generally, low index substrate materials are used to design the patch antenna but there are also some of the applications, which require the implementation of patch antenna design on high index substrate like silicon and gallium arsenide. Objective: The objective of this article is to review the design of antennas developed on high index substrate and the problems associated with the use of these materials as substrate. Also, main challenges and solutions have been discussed to improve the performance characteristics while using the high index substrates. Method: The review article has divided into various sections including the solution of the problems associated with the high index substrates in the form of micro-machining process. Along with this, types of micro machining and their applications have discussed in detail. Results: This review article investigates the various patch antennas designed with micro-machining technology and also discusses the impact of micro-machining process on the performance parameters of the patch antennas designed on high index substrates. Conclusion: By using the micro-machining process, the performance of patch antenna improves drastically but fabrication and tolerances at such minute structures is very tedious task for the antenna designers.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

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