Study on High-Speed Milling of Steam Turbine Blade Materials - Differences in Cutting Characteristics of an Unforged Ingot and a Forged Part of Stainless Steel

2017 ◽  
Vol 749 ◽  
pp. 3-8
Author(s):  
Tomonori Kimura ◽  
Takekazu Sawa ◽  
Tatsuyuki Kamijyo
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Steam Turbine ◽  
High Speed ◽  
Flank Wear ◽  
Turbine Blades ◽  
Cutting Speed ◽  
High Speed Milling ◽  
Finished Surface ◽  
Steam Turbine Blade

Stainless steel is an excellent material that has properties such as heat and corrosion resistance. Thus, stainless steel is used as a material in steam turbine blades. Steam turbine blades are mainly manufactured using two methods. One is the cutting of unforged metal ingots. Another is the cutting of forged parts. Small blades are made by cutting metal ingots. Large blades are made by cutting forged parts. The mechanical characteristics of a metal ingot and a forged part, such as hardness and toughness, are almost the same. There were not researches related to a relationship between “an unforged ingot and a forged part of stainless steel” and “the differences of the tool wear and the finished surface by high-speed milling”.In this study, the high-speed milling of stainless steel was attempted for high-efficiency cutting of a steam turbine blade. The differences of the tool wear and the finished surface in the cuttings of an unforged ingot and a forged part were investigated. In the experiment, the cutting tool was a TiAlN coating radius solid end mill made of cemented carbide. The diameter of the end mill was 5 mm, and the corner radius was 0.2 mm. The cutting speed were 100 m/min-600 m/min. The workpieces used were a metal ingot and a forged part of stainless steel. In the results, it was found that the differences of the tool wear and the finished surface in the cuttings of an unforged ingot and a forged part. In the case of the unforged ingot, the flank wear became large with increasing cutting speed. On the other hand, in the case of forged part, the flank wear rapidly increased at a cutting speed of 100 m/min. In addition, the flank wear became smaller than the cutting speed 100 m/min at the cutting speed 200 m/min. Further, the flank wear became large with increasing cutting speed at cutting speeds higher than 200 m/min. That is, the flank wear was at a minimum at a cutting speed of 200 m/min. Although it could not be confirmed the characteristic of high speed milling at an unforged ingot, it has been identified at a forged part.

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.

Study on High Speed Milling of Steam Turbine Blade Materials

2016 ◽  
Vol 1136 ◽  
pp. 251-256
Author(s):  
Tomonori Kimura ◽  
Takekazu Sawa ◽  
Tatsuyuki Kamijyo
Keyword(s):  
Stainless Steel ◽  
Titanium Alloy ◽  
Steam Turbine ◽  
Turbine Blade ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling ◽  
Steam Turbine Blade ◽  
Cutting Point

A titanium alloy and stainless steel is an excellent material having properties such as high intensity and high corrosion resistance. Therefore, a titanium alloy and a stainless steel are used as material of steam turbine blade. However, the machining efficiency of a titanium alloy and a stainless steel is a low because of difficult-to-cut materials. Especially, it is a major problem that the cutting point temperature is high and the tool life is short. In the conventional study, it is reported that the cutting point temperature is low and the tool life becomes long by cutting at the suitable cutting speed corresponding to material characteristics. This concept is known as high speed milling. In recent years, the high speed milling is actually used for the metal mold machining. In this study, the high speed milling of the titanium alloy and the stainless steel was tried for the purpose of high efficiency cutting of a steam turbine blade. In the experiment, the cutting tool used the TiAlN coating radius solid end mill made of micro grain cemented carbide. The diameter of endmill is 5mm. The corner radius is 0.2mm. And, the work piece is the titanium alloy Ti-6Al-4V and stainless steel 13Cr. The cutting speed carried out at 100m/min~600m/min. As the result, when the tool life and the surface roughness was a valuation basis, the optimum cutting speed of titanium alloy was 300m/min. On the other hand, In the case of the stainless steel, the flank wear becomes large in proportion to cutting speed. The feature of high speed milling was not able to be confirmed in the range of this experimental condition.

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.

Tool Wear in High Speed Milling of SiCp/Al2024 Metal Matrix Composites

2010 ◽  
Vol 33 ◽  
pp. 200-203 ◽  
Author(s):  
Y.J. Wang ◽  
Ming Zhou ◽  
S.N. Huang ◽  
Y.J. Zhang
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Dominant Factor ◽  
Matrix Composites ◽  
High Speed Milling ◽  
Coated Tools

This paper presents an experimental study in high speed milling of metal matrix composites (MMCs). Machining tests were carried out on a high speed milling machine by using TiAlN coated tools and chemical vapour deposition (CVD) diamond coated tools. The cutting tool wear was investigated using an optical microscope and a scanning electron microscope (SEM). The experimental results showed that flank wear is the dominant tool wear mode and abrasive wear and adhesive wear appears to be the main wear mechanism. The build-up edge (BUE) exists during the machining process at a certain speeds. Cutting speed is a dominant factor affecting the flank wear. Generally, high cutting speed lead to severe tool wear, but there seemed to be a certain cutting speed which will cause the least tool wear. Furthermore, there exists a cutting speed limit for both TiAlN coated tools and CVD coated diamond tools in high speed milling of MMCs, beyond which the edge chipping will cause the tool failure very soon.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

The Cutting Speed Influences on Tool Wear of ZTA Ceramic Cutting Tools and Surface Roughness of Work Material Stainless Steel 316L during High Speed Machining

2016 ◽  
Vol 840 ◽  
pp. 315-320 ◽  
Author(s):  
Afifah Mohd Ali ◽  
Norazharuddin Shah Abdullah ◽  
Manimaran Ratnam ◽  
Zainal Arifin Ahmad
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
High Speed ◽  
Dense Body ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Stainless Steel 316L ◽  
Crater Wear ◽  
Matlab Programming

The purpose of this research is to find the effects of cutting speed on the performance of the ZTA ceramic cutting tool. Three types of ZTA tools used in this study which are ZTA-MgO(micro), ZTA-MgO(nano) and ZTA-MgO-CeO2. Each of them were fabricated by wet mixing the materials, then dried at 100°C before crushed into powder. The powder was pressed into rhombic shape and sintered at 1600°C at 4 hours soaking time to yield dense body. To study the effect of the cutting speed on fabricated tool, machining was performed on the stainless steel 316L at 1500 to 2000 rpm cutting speed. Surface roughness of workpiece was measured and the tool wears were analysed by using optical microscope and Matlab programming where two types of wear measured i.e. nose wear and crater wear. Result shows that by increasing the cutting speed, the nose wear and crater wear increased due to high abrasion. However, surface roughness decreased due to temperature rise causing easier chip formation leaving a good quality surface although the tool wear is increased.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Effect of Pick Feed on Machining Characteristic of Up Cutting in the High-Efficient Machining by Small Diameter Radius End Mill

2019 ◽  
Vol 825 ◽  
pp. 31-38
Author(s):  
Hisaaki Nakai ◽  
Takekazu Sawa ◽  
Masahiro Anzai
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Flank Wear ◽  
Small Diameter ◽  
Hardened Steel ◽  
End Mill ◽  
High Speed Milling ◽  
Improve Efficiency ◽  
High Efficient ◽  
Coated Carbide

In order to improve efficiency of high speed milling, effects of pick feeds of up cutting and down cutting on tool wear and processing characteristics were investigated after cutting pre-hardened steel NAK 55 by TiAlN-coated carbide radius end mill. Flank wear of the tools after up cutting was less than down cutting when the pick feed was smaller than 0.1 mm, which tendency changed when the pick feed was larger than 0.3 mm.

Magnetic Damping in Turning of Stainless Steel AISI 304 for the Reduction of Machining Vibration and Tool Wear

2015 ◽  
Vol 1115 ◽  
pp. 100-103
Author(s):  
A.K.M. Nurul Amin ◽  
Muammer Din Arif ◽  
Siti Aminatuzzuhriyah B. Haji Subir ◽  
Fawaz Mohsen Abdullah
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Aisi 304 ◽  
Excited Vibration ◽  
Coated Carbide

Chatter is a type of intensive self-excited vibration commonly encountered in machining. It reduces productivity and precision, and is more noticeable in the machining of difficult-to-cut alloys like hardened steel. In such cases chatter causes excessive tool wear, especially flank wear, which in turn affects the stability of the cutting edge leading to premature tool failure, poor surface finish, and unsatisfactory machining performance. Nowadays, however, the demand is for fine finish, high accuracy, and low operation costs. Therefore, any technique which significantly reduces chatter is profitable for the industry. This paper demonstrates the viability and effectiveness of a novel chatter control strategy in the turning of (AISI 304) stainless steel by using permanent bar magnets. Reduction in chatter and corresponding tool flank wear are compared from results for both undamped and magnetically damped turning using coated carbide inserts. Special fixtures and keyway were made from mild steel in order to affix the magnets on the lathe’s carriage. The two ferrite magnets (1500 Gauss each) were placed below and beside the tool shank for damping from Z and X directions, respectively. Response surface methodology (RSM) was used to design the experimental runs in terms of the three primary cutting parameters: cutting speed, feed, and depth of cut. A Kistler 50g accelerometer measured the vibrations. The data was subsequently processed using DasyLab (version 6) software. The tool wear was measured using scanning electron microscope (SEM). Results indicate that this damping setup can reduce vibration amplitude by 47.36% and tool wear by 63.85%, on average. Thus, this technique is a simple and economical way of lowering vibration and tool wear in the turning of stainless steel.

Optimization of Parameter for HSS Tool Wear by Using Taguchi Method and Finite Element Method

2013 ◽  
Vol 315 ◽  
pp. 151-155
Author(s):  
M.R. Ibrahim ◽  
A.R. Abd. Kadir ◽  
M.S. Omar ◽  
S. Sulaiman ◽  
M.H. Osman
Keyword(s):  
Tool Wear ◽  
Taguchi Method ◽  
Surface Treatment ◽  
High Speed ◽  
Flank Wear ◽  
Simulation Analysis ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Coated Surface

This paper presents the combination between the simulation analysis of FEM (DFORM 3D) and Taguchi method approach. The Taguchi method was used to find the optimize parameter design contribute to Flank wear. The parameters were evaluated are coated surface treatment, cutting speed and feed rate. The Usuis model carried out to measure the flank wear size. Furthermore, ANOVA analysis was used out to identify the influence factors contribute to tool wear in the signal to noise ratio. The experiments were conducted on AL6061 by using High Speed Steel Tool (HSS) in face milling cutting. It shown that, the coated surface treatment is the most significant parameter which can reduce the tool wear value.

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