Planing of Cobalt-Free Tungsten Carbide Using a Diamond Tool -Cutting Temperature and Tool Wear-

2008 ◽  
Vol 389-390 ◽  
pp. 132-137 ◽  
Author(s):  
Akinori Yui ◽  
Hiroshi Matsuoka ◽  
Takayuki Kitajima ◽  
Shigeki Okuyama
Keyword(s):  
Tool Wear ◽  
Tungsten Carbide ◽  
Diamond Tool ◽  
Contact Point ◽  
Cutting Speed ◽  
Nitrogen Gas ◽  
Argon Gas ◽  
Point Temperature ◽  
Tools Wear ◽  
Cutting Point

Diamond tools wear easily under cutting tungsten carbide. To clarify the wear mechanism, the authors composed a temperature-measurement system of a cutting point using a dual-colorinfrared pyrometer and performed planing experiments. Infrared rays, emitted from the contact point between a mono-crystal-diamond tool and a cobalt-free tungsten carbide, are transmitted though the diamond tool and an optical fiber and then they are detected by the pyrometer. Before the planing experiments, rubbing experiments were performed using a mono-crystal-diamond stick and a tungsten-carbide disk. The effects of gas environments and rubbing conditions on contact-point temperature, friction coefficient, and diamond wear were experimentally investigated. Planing experiments of the tungsten carbide using mono-crystal-diamond tool, were performed. The effects of planing conditions and gas environments on cutting-point temperature and tool wear were investigated. Through the experiments the following results were obtained. Rubbing and cutting point temperature is the highest in Argon gas followed by Nitrogen gas and is the lowest in Air. Diamond-tool wear is the greatest in Argon gas, less in Nitrogen gas, and the least in Air. The reason for this is that a chemically or physically absorbed layer of oxygen or nitrogen on tungsten carbide acts as a lubricant at the contact point. Cutting-point temperature was in proportion to cutting speed. The temperature under cutting speed at 90m/min and cutting depth at 1.0μm in Air was approximately 170degrees Celsius.

Influence of Tungsten-Carbide and Cobalt on Tool Wear in Cutting of Cemented Carbides with Polycrystalline Diamond Tool

2013 ◽  
Vol 7 (4) ◽  
pp. 433-438 ◽  
Author(s):  
Junsuke Fujiwara ◽  
◽  
Keisuke Wakao ◽  
Takeshi Miyamoto ◽  
Keyword(s):  
Particle Size ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
Cemented Carbides ◽  
Large Particles

The influence of the tungsten-carbide (WC) particle size and Co contents of cemented carbides on polycrystalline diamond tool wear during turning was investigated experimentally. The main results obtained were as follows. (1) Tool wear increased with increasing Co content. (2) It is important to cut off the binder between the WC particles and the Co. (3) Cemented carbides containing small WC particles are more effective than cemented carbides containing large particles.

Molecular Dynamics Simulation Study on Diamond Tool Wear in Cutting Aluminum-Based Workpieces

2013 ◽  
Vol 579-580 ◽  
pp. 211-215
Author(s):  
Guo Jun Dong ◽  
Yuan Jing Zhang ◽  
Ming Zhou
Keyword(s):  
Molecular Dynamics ◽  
Molecular Dynamics Simulation ◽  
Tool Wear ◽  
Simulation Study ◽  
Diamond Tool ◽  
Cutting Speed ◽  
Dynamics Simulation ◽  
Cutting Depth ◽  
Factors Affecting ◽  
Definite Effect

The problem of diamond tool wear is the bottleneck for machining large metal reflector with ultraprecision cutting method. In this paper, the author performed simulation study on diamond tool wear in machining large metal reflectors, and established a molecular dynamics simulation model for dynamic simulation of tool wear; and found that in the simulation process the change in cutting speed and cutting depth had definite effect on the tool wear, and the main factors affecting the tool wear was the cutting distance.

scholarly journals Experimental Investigation of Cutting Parameters Effects on the Surface Roughness and Tools Wear during the Drilling of Fiber Reinforced Composite Materials

2019 ◽  
Vol 38 (3) ◽  
pp. 717-728 ◽  
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Tool Wear ◽  
Cutting Speed ◽  
Fiber Reinforced Polymer ◽  
Machining Parameters ◽  
Fiber Reinforced ◽  
Minimum Surface ◽  
Reinforced Polymer ◽  
Tools Wear

Optimization of the drilling parameters of the composite material is the key objective of this research, enhancing the surface roughness and minimizing the tool wear. In contrary to the other research, optimizing the machining parameters for a specific composite material for the mass productions, machining parameters are optimized for GFRP (Glass Fiber Reinforced Polymer), CFRP (Carbon Fiber Reinforced Polymer) and KFRP (Kevlar Fiber Reinforced Polymer) for the job shop production. In this research, the machining parameters are optimized for the enhanced surface roughness and minimum tool wear by varying the three types of composite material and three levels of the cutting speed. Nine experiments were performed, which were repeated twice in random manner to eliminate the biasness of the results. In these experiments, PVD (Physical Vapor Deposition) coated carbide inserts are used with the same geometry. Seventeen holes were machined in a single experiment, which surface roughness is measured by cutting the composite plate from middle of the hole and using the Countermatic surface roughness meter at different locations. Average surface roughness is determining for each set of varying parameters and plotted to observe the set of parameters for the minimum surface roughness. It has been observed that the minimum surface roughness are observed at; 1500 rpm in GFRP, 2000 rpm in CFRP and at 2500 rpm in KFRP. Finally, the wear patterns are also observed on the drill inserts using SEM (Scanning Electron Microscope) and it has been found that no prominent wear has been observed in the drill inserts, whereas, prominent depletion of coating are found at the higher cutting speed.

Study on High Speed Milling of Steam Turbine Blade Materials - Differences in Cutting Characteristics of Titanium Alloy and Stainless Steel

2016 ◽  
Vol 874 ◽  
pp. 445-449
Author(s):  
Tomonori Kimura ◽  
Tatsuyuki Kamijo ◽  
Takekazu Sawa
Keyword(s):  
Stainless Steel ◽  
Titanium Alloy ◽  
Heat Resistance ◽  
Steam Turbine ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling ◽  
Point Temperature ◽  
Steam Turbine Blade ◽  
Cutting Point

Titanium alloy and stainless steel are used as steam turbine blade materials. However, their machining efficiency is low because they are difficult-to-cut materials. In particular, the high cutting point temperature and short tool life are major problems. Highspeed milling can reduce the cutting point temperature and tool wear. In this study, highspeed milling of a titanium alloy and stainless steel was investigated for the high-efficiency cutting of a steam turbine blade. In the experiment, workpieces were made of titanium alloy Ti-6Al-4V and stainless steel 13Cr. The experiment was conducted at cutting speeds from 100 m/min to 600 m/min. The flank wear increased rapidly with increase in the cutting speed. The loss of the coating on the flank of the end mill was confirmed via energy-dispersive Xray spectroscopy analysis. It was demonstrated that the cutting point temperature was higher than the heat resistance temperature of the coating. The cutting point temperature was analyzed using AdvantEdge FEM. It was found that the cutting point temperature at a cutting speed of 350 m/min or more was higher than the heat resistance temperature of the coating. On the other hand, in the case of the stainless steel 13Cr, the flank wear increased in proportion to the cutting speed, and the loss of the coating on the flank of the end mill was also confirmed. However, the loss of the coating was less than that in the case of the titanium alloy. It was found that the high-speed milling of the stainless steel did not reach the heat resistance temperature of the coating. The cutting characteristics of the high-speed milling of the titanium alloy and stainless steel differed, which was mainly attributed to the difference in the thermal conductivity. In the high-speed milling of the titanium alloy Ti-6Al-4V and stainless steel 13Cr, it was not possible to determine the factors that result in a low cutting point temperature. If the cutting point temperature is lower than the heat resistance temperature of the coating, high-speed milling may be possible. Therefore, the ways in which the cutting point temperature can be lowered will be examined in the future.

Performance of Cryogenic Machining with Nitrogen Gas in Machining of Titanium

2011 ◽  
Vol 52-54 ◽  
pp. 2003-2008 ◽  
Author(s):  
Thet Thet Mon ◽  
J. Ramli ◽  
Jeefferie Abd Razak ◽  
Safian Sharif ◽  
V.C. Venkatesh
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Speed ◽  
Edge Condition ◽  
Stainless Steel Tube ◽  
Nitrogen Gas ◽  
Machined Surface ◽  
Cutting Insert ◽  
Cutting Zone ◽  
Coated Carbide

This research presents performance of nitrogen gas as a coolant in machining titanium. Compressed nitrogen gas stored in a cylindrical tank is supplied to the cutting zone via the stainless steel tube of 2x8x25mm (inside diameter x outside diameter x length) connected to the flexible hose and specially-designed valve with pressure controller. Machining experiments are carried out on conventional turning center. The cutting tool used is triangular insert of ISO-TPGN160308 with the holder (ISO-CTGPR3232K). The cutting insert grade is KC5010 (TiAlN3 coated carbide) as recommended by Kennametal for machining titanium. During machining, the tube is manually directed to be just-above the tool rake face and the nitrogen gas is supplied with high pressure so that the cutting zone receives an effective cooling as well as the chip brakes easily. The effectiveness of this new cooling strategy is demonstrated by the cutting edge condition and surface finish after machining at various speeds, and also by comparing with performance of conventional coolant. The result is found to be excellent in terms of relative amount of tool wear and surface finish. The cutting insert has surprisingly remained almost intact when using nitrogen gas coolant whereas severe tool wear occurred with conventional coolant even at low cutting speed. This cryogenic strategy also improved machined surface quality greatly.

The effect of oil mist supply on cutting point temperature and tool wear in driven rotary cutting

2017 ◽  
Vol 48 ◽  
pp. 158-163 ◽  
Author(s):  
Hiroyuki Sasahara ◽  
Kentarou Satake ◽  
Wataru Takahashi ◽  
Masato Goto ◽  
Hiromasa Yamamoto
Keyword(s):  
Tool Wear ◽  
Point Temperature ◽  
Rotary Cutting ◽  
Oil Mist ◽  
Cutting Point

Study on High Speed Milling of Steam Turbine Blade Materials - Difference in Cutting Characteristics by Alloying Elements of Stainless Steel

2016 ◽  
Vol 874 ◽  
pp. 439-444
Author(s):  
Tomonori Kimura ◽  
Takekazu Sawa ◽  
Tatsuyuki Kamijyo
Keyword(s):  
Stainless Steel ◽  
Steam Turbine ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
End Mill ◽  
High Speed Milling ◽  
Point Temperature ◽  
Steam Turbine Blade ◽  
Cutting Point

In this study, high speed milling of stainless steel was tried for purpose of high efficiency cutting of a steam turbine blade. In the experiment, cutting tool used TiAlN coating radius solid end mill made of cemented carbide. Diameter of end mill is 5mm. Corner radius is 0.2mm. Cutting speed carried out at 100m/s~600m/s. Work pieces was used in the experiment are four kinds of stainless steel which alloy elements differ. Mainly, content of chromium and nickel is different. There are many researches about high speed milling [1, 2].However, the researches which examined relationship between alloy elements of stainless steel and cutting characteristics on high speed milling using small diameter endmill are few.As the results, in the case of stainless steel containing much nickel, tool life becomes short in high speed cutting area. This reason is nickel has low thermal conductivity. Because the cutting point temperature becomes higher. If the coating removes, wear becomes large rapidly. In other words, maximum limit value of cutting speed was found to be dependent on heat resistance temperature of the coating.On the other hand, Chromium has the effect of improving the abrasion resistant of the workpiece. However, Flank wear was not increased in a low cutting speed area. In the range of this experimental condition, chromium didn't influence tool life. When cutting point temperature is below heat resistant temperature of the coating, it is thought that effect of the coating is maintained. Namely, it was found that appropriate cutting speed followed heat resistant temperature of the coating.

Diamond Insert Wear when Turning Rapidly Solidified Aluminium RSA 443 of High-Silicon Content

2015 ◽  
Vol 828-829 ◽  
pp. 265-271 ◽  
Author(s):  
Zwelinzima Mkoko ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Tool Wear ◽  
Diamond Tool ◽  
Natural Diamond ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Edge Wear ◽  
Rapidly Solidified

Rapid solidification of molten metals has been recently used to generate a new group of alloys having ultra-fine microstructures and high end mechanical properties. Therefore, such alloys can be successfully used in the optics industry to produce diamond machined mirrors and mould inserts for plastic lens injection. Rapidly solidified aluminium grades characterised by their ultra-fine grains can be used to replace traditional optical aluminium such as 6061-T6 which has coarse microstructure when making optics. However, there is currently no data available on the performance of these new grades in terms of diamond tool wear when machined in single-point diamond turning operation. This paper reports on the wear mechanisms of natural diamond tools when turning RSA 443 which is a new aluminium grade produced by rapid cooling process. Although this new aluminium grade enjoys fine microstructure, it is harder than traditional optical aluminium because of its increased content of silicon (about 40%). Therefore, there is a need to establish a deeper understanding of diamond tool performance when using diamond turning of optical components from this material. In this study, three machining parameters, namely cutting speed, feed rate, and depth of cut, were varied at three levels and the edge wear of the diamond inserts was observed using scanning electron microscopy after 4 km of cutting distance. The first observations from this preliminary study show that tool wear of diamond is more sensitive to the change in cutting speed than it is for other cutting parameters. Wear is relatively high (12 µm) at the lowest cutting speed (500 rpm). However, at high cutting speed (3000 rpm) the edge wear was small (3 µm). This could be attributed to the increased impacts of cut the material on the cutting edge. The study also reports on the surface finish obtained at the different combinations of cutting parameters.

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