The Analysis of Tool Wear in Milling CFRP with Different Diamond Coated Tool

2015 ◽  
Vol 667 ◽  
pp. 231-236 ◽  
Author(s):  
Xiao Fan Yang ◽  
You Sheng Li ◽  
Guo Hong Yan ◽  
Ju Dong Liu ◽  
Dong Min Yu
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Milling Process ◽  
Cutting Condition ◽  
End Mill ◽  
Reinforced Plastics ◽  
Right Hand ◽  
Coated Tool ◽  
New Type ◽  
Fiber Reinforced Plastics

Carbon fiber-reinforced plastics (CFRP) are typical difficult-to-machine materials, which is easy to produce many defects such as burrs, dilacerations, layering in milling process. And selecting the appropriate cutting tool has become the key to machining CFRP with high quality and efficiency. In the paper, the machining principle of milling CFRP with new type end mill was analyzed. The diamond coating of general right-hand end mill, cross-flute router and fine-cross-nick router were used to cutting CFRP under the same cutting condition. Through the comparative analysis of the workpiece’s surface quality and tool wear, it concluded that: compared with right-hand diamond coated end mill, cross-flute diamond coated router or fine-cross-nick diamond coated router could effectively suppress the appearance of burrs and dilacerations; abnormal coating peeling appeared in the flank face of right-hand diamond coated end mill, forming the boundary wear, which accelerated wear failure; the flank wear of diamond coated cross-flute router and fine-cross-nick router were both abrasive wear. Due to having more cutting edge than cross-flute router in cutting process, the flank wear of fine-cross-nick router was slower, and the tool life was longer. So it was more suitable for cutting CFRP.

Study on Tool Wear in Green Milling Ni-Based Superalloy

2015 ◽  
Vol 1095 ◽  
pp. 865-868
Author(s):  
Hui Wang ◽  
Yun Lu ◽  
Jing Jing Liu
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Flank Wear ◽  
Milling Process ◽  
Cutting Condition ◽  
Carbide Tool ◽  
Dry Cutting ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Ionized Air

In order to solve the difficult machining problem of Ni-based superalloy, the water vapor and ionized air was applied as coolant and lubricant in milling process. The tool wear experiments on water vapor, ionized air, wet and dry cutting with carbide tool YG6A machining Ni-based superalloy GH4169 was carried out. The result showed that tool wear was quickly on milling GH4169 with carbide tool YG6A, and increased with the cutting speed.The flank wear land was uneven and the boundary wear was serious. During the ionized air condition the flank wear was more slowly than wet and dry cutting condition, the values of flank wear were reduced about 15 and 10 percent respectively. In addition, the result showed that The milling force and machined surface roughness increased with the flank wear.

scholarly journals Delamination Study in Edge Trimming of Basalt Fiber Reinforced Plastics (BFRP)

Materials ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 1418 ◽  
Author(s):  
Maria Navarro-Mas ◽  
Juan García-Manrique ◽  
Maria Meseguer ◽  
Isabel Ordeig ◽  
Ana Sánchez
Keyword(s):  
Tool Wear ◽  
Volume Fraction ◽  
End Milling ◽  
Basalt Fiber ◽  
Depth Of Cut ◽  
Fiber Reinforced ◽  
Fiber Volume ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Edge Trimming

Although there are many machining studies of carbon and glass fiber reinforced plastics, delamination and tool wear of basalt fiber reinforced plastics (BFRP) in edge trimming has not yet studied. This paper presents an end milling study of BFRP fabricated by resin transfer molding (RTM), to evaluate delamination types at the top layer of the machined edge with different cutting conditions (cutting speed, feed rate and depth of cut) and fiber volume fraction (40% and 60%). This work quantifies delamination types, using a parameter Sd/L, that evaluates the delamination area (Sd) and the length (L), taking into account tool position in the yarn and movement of yarns during RTM process, which show the random nature of delamination. Delamination was present in all materials with 60% of fiber volume. High values of tool wear did not permit to machine the material due to an excessive delamination. Type II delamination was the most usual delamination type and depth of cut has influence on this type of delamination.

Basic Investigation of Tool Wear

1963 ◽  
Vol 85 (1) ◽  
pp. 33-37 ◽  
Author(s):  
H. Takeyama ◽  
R. Murata
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Condition ◽  
Rate Process ◽  
Mechanical Abrasion ◽  
Fundamental Investigation ◽  
First Approximation ◽  
Basic Investigation

This paper treats a fundamental investigation of tool wear and tool life mainly from the viewpoint of flank wear. The result reveals that the mechanism of tool wear in turning can be classified into two basic types: The mechanical abrasion which is directly proportional to the cutting distance and independent of the temperature; and the other is, so to speak, a physicochemical type which is considered to be a rate process closely associated with the temperature, of course. Although it depends upon the cutting condition which type of wear plays a more important role, the latter is predominant under usual conditions. According to the analyses and the experimental results, it has been found out that the tool life from the standpoint of flank wear can be predicted to a first approximation by the initial cutting temperature.

Experimental Study on Turning of Alloy Cast Iron with Coated and Uncoated Tools

2010 ◽  
Vol 135 ◽  
pp. 265-270 ◽  
Author(s):  
Q.C. Wang ◽  
Qing Long An ◽  
Ming Chen ◽  
Gang Liu ◽  
Yun Shan Zhang
Keyword(s):  
Surface Roughness ◽  
Cast Iron ◽  
Tool Wear ◽  
Great Influence ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Tool ◽  
Coated Carbide ◽  
Alloy Cast Iron ◽  
Alloy Cast

Alloy cast iron cylinder is the mainstream product used in engine nowadays. However, the machinability of alloy cast iron is poor because of its enhanced mechanical properties. In this paper, turning experiment has been conducted to study machinability of alloy cast iron with uncoated and coated carbide tools under dry cutting condition. The results of the experiment indicated that the turning performance of alloy cast iron with coated tool was much better than uncoated tool in terms of cutting force coefficients and tool wear. Feed rate has a great influence on surface roughness, and appropriate tool wear is benefit of finished surface roughness.

Tool Wear Behavior in Turning Inconel 718 with Coated Inserts

2012 ◽  
Vol 499 ◽  
pp. 348-352 ◽  
Author(s):  
Xiao Li Zhu ◽  
Song Zhang ◽  
X.L. Xu ◽  
H.G. Lv
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Cutting Condition ◽  
Tool Holder ◽  
Final Failure ◽  
Coated Carbide

In the present study, an experimental investigation has been carried out in an attempt to monitor tool wear progress in turning Inconel 718 with coated carbide inserts under the wet cutting condition. First, each experimental test was conducted with a new cutting edge and the turning process was stopped at a certain interval of time. Secondly, the indexable insert was removed from the tool holder and the flank wear of the insert was measured using a three-dimensional digital microscopy (VHX-600E); and then the insert was clamped into the tool holder for the next turning experiment. The final failure of tool wear surfaces were examined under a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectrometer (EDS). It is indicated that significant flank wear was the predominant failure mode, and the abrasive, adhesive and oxidation wear were the most dominant wear mechanisms which directly control the deterioration and final failure of the cutting tools.

Performance of Tools Design when Helical Milling on Carbon Fiber Reinforced Plastics (CFRP) Aluminum (Al) Stack

2013 ◽  
Vol 465-466 ◽  
pp. 1075-1079 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Z. Mohid ◽  
M.R. Hamzah ◽  
A.F. Yusuf ◽  
N.A. Rahman
Keyword(s):  
Milling Process ◽  
Helical Milling ◽  
Machining Parameters ◽  
Reinforced Plastics ◽  
Comparable Performance ◽  
Hole Making ◽  
Milling Characteristics ◽  
The Common ◽  
Fiber Reinforced Plastics

Hole making process is not strictly to the drilling technique where others machining could also influence to the quality in CFRP hole.Therefore, helical milling process becomes as an alternative method to produces bore on CFRP plate thus minimizing the defects. The common defects on CFRP are delamination, splintering and cracking. Meanwhile, if the CFRP stacking together with aluminum plate, burr at exit hole of aluminium plate is produced. Therefore, it is essential to control the critical machining parameters to assure a good quality of the hole. The main objective of this project is to improve the hole quality of CFRP/AL stack in terms of surface roughness using helical milling technique. In addition the cutting force and temperature will be measured as well. There are three levels of cutting speeds; two levels of feed rate and depth per helical path are made accordingly to helical milling characteristics. It was found that all tool design exhibit comparable performance for helical milling process on CFRP/Al stack.

Tool Wear in Ball-End Milling of Cr12MoV Die Steel Using an Indexable Cutter with the Asymmetric Inserts

2012 ◽  
Vol 500 ◽  
pp. 111-116
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Xin Qiang Zhuang ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Die Steel ◽  
Ball End Milling ◽  
Diffusion Wear ◽  
Flank Face ◽  
And Diffusion

Tool wear was investigated at the different cutting conditions in rough ball-end milling of Cr12MoV die steel using an indexable cutter with asymmetric inserts. The wear patterns on rake face and flank face of major insert and minor insert, and chip patterns were observed by VHX-600E large depth-of-view 3-D scanner. The relationships of tool wear and cutting conditions, and their mechanisms were discussed. The tool life was determined by the flank wear at No. 1 cutting condition. At Nos. 2-8 cutting conditions, the life of major inset and minor insert were determined by the wear of their rake faces and flank faces respectively. At No. 8 cutting condition, the tool wear was dominated by boundary wear, adhesion and diffusion wear, and the slight chipping. Both type and color of chips identified the cutting stability at the different cutting conditions.

Software Development and Data Processing of Tool Wear Based on Mapping Measurement

2011 ◽  
Vol 383-390 ◽  
pp. 4971-4976 ◽  
Author(s):  
Song Guo ◽  
Chen Zhang ◽  
Xi Hui Liu
Keyword(s):  
Tool Wear ◽  
Data Processing ◽  
Measurement Method ◽  
Flank Wear ◽  
Great Influence ◽  
Least Square Method ◽  
Milling Process ◽  
Processing Method ◽  
Least Square ◽  
Data Processing Method

In NC milling process, tool wear has great influence on the machining quality of product. In this paper, a mapping measurement method is used to obtain tool wear and a data processing method is proposed to deal with the data getting from the measurement. First, tool wear along radius of tool’s cross-section, which is called radial wear, can be obtained by mapping measurement method. Then tool flank wear can be easily calculated based on the established relationship between radial wear and flank wear. In order to get radial wear, we process those measured data that are obtained from mapping measurement. In this process, least square method is adopted to fit these data to get the radius of section circle at a certain position. So the radial wear can be obtained by comparing the radius of the fitting circle and the original radius of tool at a certain section. Finally, the data processing software is realized by using Visual C++ development tool according to the designed data processing method of tool wear.

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