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 Prediction of Tool Lifetime and Surface Roughness for Nickel-Based Waspaloy

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Shao-Hsien Chen ◽  
Chung-An Yu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Predictive Values ◽  
Actual Surface ◽  
Wide Range

In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.

Machinability Improvement on High Speed Ultrasonic Turning - The Effect of Tool Oscillating Direction and Tool Chip Shape

2016 ◽  
Vol 874 ◽  
pp. 302-307
Author(s):  
Keisuke Hara ◽  
Ryo Sasaki ◽  
Hiromi Isobe
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Processing Speed ◽  
High Speed ◽  
Principal Direction ◽  
Cutting Speed ◽  
Soft Magnetic ◽  
Chip Shape ◽  
Fine Surface ◽  
Ultrasonic Cutting

Ultrasonic cutting is a technique that can improve machinability such as fine surface, reduce tool worn out and etc. To improve processing speed of ultrasonic cutting is difficult due to the effects of tool oscillation are invalidated when cutting speed exceeds maximum tool oscillating velocity. In previous report, high speed principal direction ultrasonic turning experiments for stainless steel were carried out to improve processing speed and products quality. In ultrasonic turning, tool worn out and built up edge generation were reduced compare with ordinary turning. In this study, the effects of tool oscillating direction and tool chip shape for cutting properties of soft magnetic stainless steel were investigated. Cutting properties such as turned surface roughness, cutting force and ejected chip were compared.

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

scholarly journals Tool Wear, Surface Topography, and Multi-Objective Optimization of Cutting Parameters during Machining AISI 304 Austenitic Stainless Steel Flange

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 972 ◽  
Author(s):  
Xiaojun Li ◽  
Zhanqiang Liu ◽  
Xiaoliang Liang
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Wear ◽  
Surface Defects ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Aisi 304 ◽  
304 Austenitic Stainless Steel ◽  
Optimization Of Cutting Parameters

The application of AISI 304 austenitic stainless steel in various industrial fields has been greatly increased, but poor machinability classifies AISI 304 as a difficult-to-cut material. This study investigated the tool wear, surface topography, and optimization of cutting parameters during the machining of an AISI 304 flange component. The machining features of the AISI 304 flange included both cylindrical and end-face surfaces. Experimental results indicated that an increased cutting speed or feed aggravated tool wear and affected the machined surface roughness and surface defects simultaneously. The generation and distribution of surface defects was random. Tearing surface was the major defect in cylinder turning, while side flow was more severe in face turning. The response surface method (RSM) was applied to explore the influence of cutting parameters (e.g., cutting speed, feed, and depth of cut) on surface roughness, material removal rate (MRR), and specific cutting energy (SCE). The quadratic model of each response variable was proposed by analyzing the experimental data. The optimization of the cutting parameters was performed with a surface roughness less than the required value, the maximum MRR, and the minimum SCE as the objective. It was found that the desirable cutting parameters were v = 120 m/min, f = 0.18 mm/rev, and ap = 0.42 mm for the AISI 304 flange to be machined.

scholarly journals Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Harun Gokce
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Taguchi Method ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Tool Wear ◽  
Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

Influence of Cutting Parameters and Tool Wear on Martensitic Stainless Steel Surface Integrity After a Face Milling Process

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Surface Integrity ◽  
Surface Finish ◽  
Cutting Tool ◽  
Fatigue Behavior ◽  
Cutting Speed ◽  
Stainless Steel Surface ◽  
Workpiece Material

Surface finish is one of the most relevant aspects of machining operations, since it is one of the principle methods to assess quality. Also, surface finish influences mechanical properties such as fatigue behavior, wear, corrosion, etc. The feed, the cutting speed, the cutting tool material, the workpiece material and the cutting tool wear are some of the most important factors that affects the surface roughness of the machined surface. Due to the importance of the martensitic 416 stainless steel in the petroleum industry, especially in valve parts and pump shafts, this material was selected to study the influence of the feed per tooth and cutting speed on tool wear and surface integrity. Also the influence of tool wear on surface roughness is analyzed. Results showed that high values of roughness are obtained when using low cutting speed and feed per tooth and by using these conditions tool wear decreases prolonging tool life.

An Experimental Study on Finish Dry Milling of AISI 321 Stainless Steel

2016 ◽  
Vol 861 ◽  
pp. 26-31 ◽  
Author(s):  
Peng Guo ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Jun Wang ◽  
Han Lian Liu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Aisi 321 ◽  
Coated Cemented Carbide

The milling of AISI 321 stainless steel which has wide engineering applications particularly in automobile, aerospace and medicine is of great importance especially in the conditions where high surface quality is required. In this paper, L16 orthogonal array design of experiments was adopted to evaluate the machinability of AISI 321 stainless steel with coated cemented carbide tools under finish dry milling conditions, and the influence of cutting speed ( V ), feed rate ( f ) and depth of cut ( ap ) on cutting force, surface roughness and tool wear was analysed. The experimental results revealed that the cutting force decreased with an increase in the cutting speed and increased with an increase in the feed rate or the depth of cut. The tool wear was affected significantly by the cutting speed and the depth of cut, while the effect of the feed rate on the tool wear was insignificant. With the cutting speed increased up to 160 m/min, a decreasing tendency in the surface roughness was observed, but when the cutting speed was further increased, the surface roughness increased. The effect of the feed rate and the depth of cut on the surface roughness was slight.

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.

Effect of Cutting Speed on Ultrasonically Added Turning in Soft Magnetic Stainless Steel

2016 ◽  
Vol 1136 ◽  
pp. 390-393 ◽  
Author(s):  
Keisuke Hara ◽  
Hiromi Isobe
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Processing Speed ◽  
High Speed ◽  
Principal Direction ◽  
Cutting Speed ◽  
Soft Magnetic ◽  
Fine Surface ◽  
Ultrasonic Cutting ◽  
Quality Surface

Ultrasonic cutting is a technique that can improve machinability such as fine surface, reduce tool worn out and etc. To improve processing speed of ultrasonic cutting is difficult due to the effects of tool oscillation are invalidated when cutting speed exceeds maximum tool oscillating velocity. In this study, high speed principal direction ultrasonic turning experiments for soft magnetic stainless steel were carried out to investigate effects of cutting speed and products quality. Surface roughness, chip worn out and built up edge were investigated in this study. In case of ultrasonic turning, tool worn out and built up edge generation were reduced compare with ordinary turning. High speed ultrasonic cutting can improve cutting performances in phase of turned surface quality, cutting force and processing speed.

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