Study on the Wear of Cutting-Tools Used in Dry Machining of Cu-10wt%Al-5wt%Ni-5wt%Fe Alloy

2021 ◽  
Vol 413 ◽  
pp. 194-200
Author(s):  
Marcos de Aguiar Guimarães ◽  
Givanildo Alves dos Santos ◽  
Mauricio S. Nascimento ◽  
Rogerio Teram ◽  
Vinicius Torres dos Santos ◽  
...  
Keyword(s):  
Tool Wear ◽  
Copper Alloys ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Lower Surface ◽  
Raw Material ◽  
Machining Process ◽  
Dry Machining ◽  
Aluminium Bronze

Aluminium bronze alloys are special copper alloys that have a machinability rate from 20 to 40% compared to free cutting brasses, so the cutting parameters and type of tools suitable for machining of these materials may be very different for other copper alloys. Also, due to the relative high costs of the raw material, the absence of contamination of the chips by cutting fluids improve its intrinsic resales value and encourage the use of machining process without coolant. The aim of this work is to evaluate the tool wear mechanisms in the finishing machining of the Cu-10wt%Al-5wt%Ni-5wt%Fe aluminium-bronze alloy with carbide and cermet inserts at different cutting speeds under dry machining condition. The turning of material showed lower surface roughness in higher speed conditions and better dimensional stability at lower speeds. It was observed the formation of continuous chips, but of little volume occupied. The scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) analyses of tool wear show the adhesion as the main tool wear mechanism, followed by abrasion. At the lower cutting speed, the adhesion wears affected significantly the surface finish, reducing the tool life in comparison to the higher speeds.

scholarly journals Influence of Tool Wear on Form Deviations in Dry Machining of UNS A97075 Alloy

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 958
Author(s):  
Francisco Javier Trujillo Vilches ◽  
Sergio Martín Béjar ◽  
Carolina Bermudo Gamboa ◽  
Manuel Herrera Fernández ◽  
Lorenzo Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
General Trend ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Adhesion Wear ◽  
Tool Wear Mechanisms ◽  
Tool Wear Mechanism ◽  
High Feed ◽  
Dry Conditions

Geometrical tolerances play a very important role in the functionality and assembly of parts made of light alloys for aeronautical applications. These parts are frequently machined in dry conditions. Under these conditions, the tool wear becomes one of the most important variables that influence geometrical tolerances. In this work, the influence of tool wear on roundness, straightness and cylindricity of dry-turned UNS A97075 alloy has been analyzed. The tool wear and form deviations evolution as a function of the cutting parameters and the cutting time has been assessed. In addition, the predominant tool wear mechanisms have been checked. The experimental results revealed that the indirect adhesion wear (BUL and BUE) was the main tool-wear mechanism, with the feed being the most influential cutting parameter. The combination of high feed and low cutting speed values resulted in the highest tool wear. The analyzed form deviations showed a general trend to increase with both cutting parameters. The tool wear and the form deviations tend to increase with the cutting time only within the intermediate range of feed tested. As the main novelty, a relationship between the cutting parameters, the cutting time (and, indirectly, the tool wear) and the analyzed form deviations has been found.

scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

Influência do Avanço da Ferramenta e do Uso de Fluido de Corte na Rugosidade em Usinagem de Torneamento Cilíndrico Externo de Alumínio

2018 ◽  
Vol 13 (13) ◽  
pp. 13
Author(s):  
Clauber Roberto Melo Marques ◽  
Paulo Henrique Castagnel
Keyword(s):  
Mass Spectrometry ◽  
Cutting Speed ◽  
Tool Material ◽  
Chemical Characterization ◽  
Surface Characteristics ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Dry Machining ◽  
Average Roughness

As características superficiais de uma peça usinada são resultantes de vários fatores, entre eles pode-se citar o material da ferramenta utilizada, geração de calor e parâmetros de corte. Este trabalho teve como objetivo principal verificar a influência do avanço da ferramenta e do uso de fluido de corte em usinagem analisando a rugosidade de superfícies de peças de alumínio usinadas por torneamento cilíndrico externo, em um equipamento CNC Romi Centur 30D com comando Siemens, variando-se a velocidade de avanço da ferramenta, assim como a usinagem a seco e com fluido de corte. Foi realizada uma análise da caracterização química por Espectrometria de Massa para identificar a constituição do material utilizado. Foi executado o processo de usinagem em 10 peças de alumínio, com velocidade de corte de 220 m/min em todos os testes, variando-se o avanço da ferramenta (0,1, 0,15, 0,2, 0,25, 0,30 mm/rot), e para cada valor de avanço diferente foi realizado um ensaio à seco e um com fluido de corte. Após a usinagem as peças foram analisadas utilizando-se um rugosímetro Mitutoyo modelo SJ-310, para medição da Rugosidade Média (Ra) resultante. Concluiu-se que para valores de avanço de ferramenta de até 0,25 mm/rot, com velocidade de corte de 220 m/min, a presença do fluido de corte na usinagem não apresentou melhoria no resultado final. Somente com avanço de 0,30 mm/rot a presença do fluido de corte se mostrou mais eficiente que a usinagem a seco.Palavras-chave: Usinagem. Alumínio. Rugosidade. AbstractThe surface characteristics of a machined part is the result of several factors, among them the tool material used, heat generation and cutting parameters. This work had as main objective the analysis of the surface roughness of aluminum parts machined by external cylindrical turning in a CNC Romi Centur 30D equipment with Siemens command, varying the speed of tool advance, as well as the dry machining and with cutting fluid. An analysis of the chemical characterization was performed by Mass Spectrometry to identify the constitution of the material used. The machining process was carried out in 10 pieces of aluminum, with a cutting speed of 220 m/min in all tests. The tool advance (0,1, 0,15, 0,2, 0,25, 0,30 mm/rot), and for each different feed rate a dry test and one with cutting fluid were performed. After machining, the parts were analyzed using a Mitutoyo model SJ-310 rugosimeter to measure the resulting Average Roughness (Ra). It was concluded that for tool feed values up to 0.25 mm/rot, with a cutting speed of 220 m/min, the presence of the cutting fluid in the machining did not show improvement in the final result. Only with an advance of 0.30 mm/rot the presence of the cutting fluid was more efficient than the dry machining. Keywords: Machining, Aluminum, Roughness.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

2011 ◽  
Vol 189-193 ◽  
pp. 3142-3147 ◽  
Author(s):  
Dong Qiang Gao ◽  
Zhong Yan Li ◽  
Zhi Yun Mao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

Empirical Expression of Tool Wear When Face Milling 416 SS

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Increase Tool Life ◽  
The Cost

During a machining process, cutting parameters must be taken into account, since depending on them the cutting edge starts to wear out to the point that tool can fail and needs to be change, which increases the cost and time of production. Since wear is a negative phenomenon on the cutting tool, due to the fact that tool life is reduced, it is important to optimize the cutting variables to be used during the machining process, in order to increase tool life. This research is focused on the influence of cutting parameters such as cutting speed, feed per tooth and axial depth of cut on tool wear during a face milling operation. The Taguchi method is applied in this study, since it uses a special design of orthogonal array to study the entire parameters space, with only few numbers of experiments. Also a relationship between tool wear and the cutting parameters is presented. For the studies, a martensitic 416 stainless steel was selected, due to the importance of this material in the machining of valve parts and pump shafts.

Dry Machining of T6061 Aluminium Alloy Using Titanium Carbonitride (TiCN) Coated Tools

2013 ◽  
Vol 652-654 ◽  
pp. 2129-2133
Author(s):  
Tasnim Firdaus Ariff ◽  
Nur Najwa Sofian ◽  
Nor Hayati Che Mat
Keyword(s):  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Titanium Carbonitride ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Coated Tools ◽  
Percentage Difference ◽  
Optimum Cutting

In metal cutting process, the use of cutting fluids, cooling and easy chip removal causes long-term effects of cutting fluids disposal into environment. Research has also proven the health hazards on manufacturing workers who coming in direct contact with cutting fluids. Currently it is highly competitive or end-user of metal workings fluid to reduce cost and improve productivity. Considering the high cost and problems associated with health and safety, it would be desirable if the use of cutting fluids be omitted. This study investigates the flank wear behavior of coated Titanium Carbonitride (TiCN) coated tools in dry and wet machining of T6061 Aluminum alloy with the aim of obtaining the optimum cutting speed for dry and wet machining respectively. By using specific depths of cut 0.2 and 0.6 mm with feed rates of 0.4 and 0.8 mm/rev respectively, the wear was investigated for 3 different high cutting speeds; 290, 360 and 446 mm/min. Results of dry machining was compared with traditional wet machining process. The temperature of tool tip, machining time and tool wear were recorded. Wear rate of the tool increases with the increasing cutting speed and parameters for both dry and wet machining. Wear percentage difference for dry machining was found to be 21-37 % (d = 0.2 mm and f = 0.4 mm/rev) and 41 - 58% (d = 0.6 mm and f = 0.8 mm/rev) higher than wet machining. The optimum cutting speed for both cutting parameters is 446 m/min for dry and wet machining. Tool tip temperature for dry machining is found to be 14 - 16 % higher than wet machining for both cutting parameters. It is observed that dry machining is suitable for high speed intermittent cutting operations.

scholarly journals Tool wear development in gear skiving process of quenched and tempered internal gears

2021 ◽  
Author(s):  
Tassilo Arndt ◽  
Jan Klose ◽  
Michael Gerstenmeyer ◽  
Volker Schulze
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Performance ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Machining Process ◽  
Process Understanding ◽  
Complex Process ◽  
Drive Trains

AbstractGear skiving is a highly productive machining process, especially for manufacturing of high strength internal gears as required for high performance electric drive trains. However, the complex process kinematics cause intense variations of the effective cutting parameters during tool engagement. Thus, particularly the tool must meet high requirements to achieve long tool life at required workpiece quality. These requirements are amplified even more when machining quenched and tempered materials from the massive blank.In the presented study, the influence of various key factors on the tool wear development in gear skiving process are quantified. In several tests, the cutting speed, workpiece tensile strength, cooling lubricant strategy, as well as the cutting strategy are varied in order to optimize tool life. Therefore, single-tooth tests on quenched and tempered internal gears from 31CrMoV9 (AISI 4340) steel are conducted and wear flank land width evolution of the tools is examined. In addition, the workpiece is evaluated with regard to surface quality. Results reveal that different factor level combinations can have various effects on tool wear characteristics and therefore on tool life. The correlations presented provide recommendations for practical application and contribute to deeper process understanding.

Analysis of the Machinability of Aluminium Alloys UNS A97050-T7 and UNS A92024-T3 during Short Dry Turning Tests

2011 ◽  
Vol 264-265 ◽  
pp. 931-936 ◽  
Author(s):  
B. de Agustina ◽  
A. Saa ◽  
Mariano Marcos Bárcena ◽  
E.M. Rubio
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloys ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Environmental Conservation ◽  
Machining Process ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Production Technologies

The aluminium alloys are widely employed in the aeronautical, aerospace and automotive industries in the most important manufacturing processes. This is due to the fact they have a high resistance even at high temperatures as well as a low density. Nevertheless, these materials can commonly show problems associated with the heat generated during the machining process that reduces their machinability. For this reason, cutting fluids are still widely used. However, the growing social preoccupation towards environmental conservation has made it necessary to develop cleaner production technologies as dry machining, in which no cutting fluids are employed. This situation makes necessary to look for combinations of cutting parameters and types of tools that improve the machining in those extreme work. In this study, the UNS A97050-T7 and UNS A92024-T3 aluminium alloys were analyzed in terms of surface roughness and the morphology of chips obtained, using tools with TiN coating. It was found that the surface quality of the aluminium UNS A97050-T7 and UNS A92024-T3 bars improves with the descent of the feed and with the increase of the cutting speed, being the feed the cutting parameter more influential on the surface roughness. Thus the machining of the UNS A92024-T3 allows obtaining shorter chips than the UNS A97050-T7.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

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