PCD Reamer for Machining Cylinder Head

2011 ◽  
Vol 175 ◽  
pp. 321-325
Author(s):  
Yong Guo Wang ◽  
Xiao Guang Chen ◽  
Gang Liu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cylinder Head ◽  
Cutting Tools ◽  
Al Alloy ◽  
Cutting Efficiency ◽  
German Company ◽  
Machined Parts ◽  
Automobile Parts ◽  
Better Than

PCD cutting tools have been widely used in manufacturing main automobile parts such as Al-alloy cylinder head and block. Being used PCD cutting tools, the cutting efficiency and precision of the machined parts could be increased. 4 blades PCD reamer used for reaming Al-alloy cylinder head has been development. Results showed that the tool life of this reamer is 2 times than the similar tools made by German company, the surface roughness is Ra0.2, better than the required Ra0.8, the cylindricity is 0.003, better than the required 0.006.

Development of PCD Combined Tool for Machining Cylinder Block

2010 ◽  
Vol 426-427 ◽  
pp. 477-480
Author(s):  
Yong Guo Wang ◽  
G. Liu ◽  
J.S. Zhang ◽  
Jian Bo Yu ◽  
M. Li
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cylinder Block ◽  
Al Alloy ◽  
Japanese Company ◽  
Pcd Tool ◽  
Better Than

4 blades PCD combined tool used for hole reaming and chamfer milling Al-alloy cylinder block has been developed. Results showed that the tool life of this PCD tool is 21.5 times than the former carbide tools made by Japanese company, the surface roughness of the hole is Ra0.2, better than the required Ra3.2, the 90 chamfer surface roughness is Ra1.6, better than the required Ra25.

scholarly journals Experimental Investigation on the Advantages of Dry Machining over Wet Machining during Turning of AISI 1020 Steel

2021 ◽  
Vol 8 ◽  
pp. 12-25
Author(s):  
Boki Dugo Bedada ◽  
Guteta Kabeta Woyesssa ◽  
Moera Gutu Jiru ◽  
Besufekad Negash Fetene ◽  
Tekle Gemechu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Dry Machining ◽  
Dry Turning ◽  
Total Cost ◽  
Cemented Carbide Tool ◽  
Lathe Machine ◽  
The Cost

In this study, the experiment was conducted to investigate the advantage of dry machining over wet machining during turning of AISI 1020 steel using cemented carbide tool on a CNC lathe machine. Surface roughness and cutting temperature were measured by VOGEL surface roughness tester and infrared thermometer respectively. The experiments were conducted based on Taguchi L9 orthogonal array design. Surface roughness, cutting temperature, tool life, and machining cost were analyzed graphically. The average surface roughness and cutting temperature achieved with wet machining was 2.01 μm and 26.540C, which was 17.41% and 44.86% respectively, lower than dry machining. The high cutting temperature in dry turning result in short tool life, which was 41.15% shorter than wet turning. The machining cost of wet turning was about 56% greater than the cost of dry turning. The cost of coolant in wet turning is 42.88% greater than that of the cutting tools. The highest cost was shared by tool cost, which was 81.33% of the total cost for dry turning, while 70.00% of the total cost was shared by coolant cost for wet turning. Results revealed that dry turning is more economical than wet turning.

Investigating of Tool Wear, Tool Life and Surface Roughness When Machining of Nickel Alloy 242 with Using of Different Cutting Tools

2008 ◽  
Vol 1 (3) ◽  
pp. 222-230 ◽  
Author(s):  
H.H. Habeeb ◽  
K.A. Abou-El-Ho ◽  
Bashir Mohamad ◽  
Jahara A. Ghani ◽  
K. Kadirgama
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Nickel Alloy ◽  
Tool Life ◽  
Cutting Tools ◽  
Wear Tool

MECHANICAL PROPERTIES AND CUTTING PERFORMANCE OF ELECTROLESS TERNARY NI-W-P COATED CUTTING TOOLS

2017 ◽  
Vol 79 (5-2) ◽  
Author(s):  
Mohd Sanusi Abdul Aziz ◽  
Bahrin Ikram Redzuwan ◽  
Muhammad Zaimi ◽  
Raja Izamshah ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Surface Roughness ◽  
Tool Life ◽  
Electrical Power ◽  
Cutting Tools ◽  
Electroless Nickel ◽  
Cutting Performance ◽  
High Deposition Rate ◽  
Nickel Deposition ◽  
Plating Bath

This paper presents a new approach of electroless nickel deposition (END) on cutting tools as to enhance tool performance. END involves several reactions in aqueous solution and is performed without using electrical power. The cutting performance of electroless ternary Ni-W-P alloy-coated cutting tools that were prepared in plating baths with different pH levels and with the addition of heat treatment was investigated. The cutting tool life was evaluated during machining on AISI D2 steel followed by measurement of surface roughness. Experimental results showed that END cutting tools produced from a plating bath with a pH of 8.5 with heat treatment resulted in the longest tool life, which was 7 minutes 32 seconds, and the lowest surface roughness, which was 0.412 μm. High deposition rate and high thickness of coating obtained under such pH condition were found to be the main factors in enhancing tool life. Furthermore, the addition of heat treatment increases the hardness and improves the coating surface.

Investigation of Tool Wear, Tool Life and Surface Roughness when Machining AISI D2 Hardened Steel Using PVD TiAlN Coated Carbide Tools

2013 ◽  
Vol 465-466 ◽  
pp. 1098-1102 ◽  
Author(s):  
Noor Hakim Rafai ◽  
Mohd Amri Lajis ◽  
N.A.J. Hosni
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Material Removal ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Tool Failure ◽  
Aisi D2 ◽  
Wear Tool ◽  
Coated Carbide

This paper discussed the behavior of cutting tool in terms of tool wear, tool life and surface roughness when machining an AISI D2 hardened steel. An experimental test was conducted at different cutting speeds (Vc) and radial depth of cut (ae) using PVD TiAlN coated carbide tool under dry condition. Tool failure modes and tool wear mechanism for all cutting tools were examined at various cutting parameters. Flank wear was found to be the predominant tool failure for cutting tools. The highest volume material removal (VMR) attained was 3750 mm3 meanwhile the highest tool life (TL) was 9.69 min. The surface roughness (Ra) values from 0.09 to 0.24 μm can be attained in the workpiece with a high material removal. The relationship of tool wear performance and surface integrity was established to lead an optimum parameter in order to have high material removal, maximum tool life as well as acceptable surface finish.

scholarly journals Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1628
Author(s):  
Mohd Fathullah Ghazali ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Paweł Pietrusiewicz ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Potential Use

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

scholarly journals Surface roughness of machined wood and advanced engineering materials and its prediction: A review

2021 ◽  
Vol 13 (5) ◽  
pp. 168781402110176
Author(s):  
Zhao-Wei Zhong
Keyword(s):  
Surface Roughness ◽  
Minimum Quantity Lubrication ◽  
Al Alloy ◽  
Swarm Optimization ◽  
Abrasive Jet Machining ◽  
Engineering Materials ◽  
Glass Surfaces ◽  
Rapidly Solidified ◽  
Ductile Streaks ◽  
Better Than

This article discusses the surface roughness of wood and advanced engineering materials after machining and its prediction. The topics are surface roughness of precision-machined advanced engineering materials, machining of WC and Inconel, rapidly solidified Al alloys, surface roughness of wood materials, and prediction of surface roughness. Findings include that ductile streaks on silicon and glass surfaces ground or lapped with inexpensive machines largely reduced the polishing time to obtain the required surface roughness. Abrasive jet machining could remove the patterns from recycled wafers and improve the surface roughness. The roughness of WC-Co coatings was significantly improved by using the method of fast regime fluidized bed machining. As beryllium is a toxic element, the rapidly solidified Al alloy may be a good insert material to replace BeCu. Higher bonding strengths resulted from rougher surfaces of wood samples. Wood samples had reduced bonding strengths after soaking in water. Optimum artificial neural networks (ANNs) with necessary inputs could accurately predict the roughness values. ANNs trained using particle swarm optimization and genetic algorithms could predict surface roughness better than typical ANNs. Minimum quantity lubrication is a hot research topic to minimize the amount of the fluid for cost and environmental considerations.

Effect of Tool Wear on Tool Life and Surface Finish when Machining DF-3 Hardened Tool Steel

2013 ◽  
Vol 315 ◽  
pp. 241-245 ◽  
Author(s):  
Ali Davoudinejad ◽  
M.Y. Noordin ◽  
Danial Ghodsiyeh ◽  
Sina Alizadeh Ashrafi ◽  
Mohsen Marani Barzani
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Tool Steel ◽  
Wear Mechanism ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Mixed Ceramic

Hard turning is a dominant machining operation performed on hardened materials using single-point cutting tools. In recent years, hard turning operation has become more and more capable with respect to various machinability criteria. This work deals with machinability of hardened DF-3 tool steel with 55 ±1 HRC hardness at various cutting conditions in terms of tool life, tool wear mechanism and surface roughness. Continuous dry turning tests were carried out using coated, mixed ceramic insert with honed edge geometry. Two different cutting speeds, 100 and 210 m/min, and feed rate values of 0.05, 0.125 and 0.2 mm/rev were used with a 0.2 mm constant depth of cut for all tests. Additionally scanning electron microscope (SEM) was employed to clarify the different types of wear. As far as tool life was concerned, best result was achieved at lowest cutting condition whereas surface roughness values decreased when operating at higher cutting speed and lower feed rate. Additionally maximum volume of material removed is obtained at low cutting speed and high feed rate. Dominant wear mechanism observed during the experiments were flank and crater wear which is mainly caused by abrasive action of the hard workpiece material with the ceramic cutting tools.

The Influence of Copy Strategy on the Tool Life of Ball End Mills and Achieved Surface Roughness

2016 ◽  
Vol 686 ◽  
pp. 240-245
Author(s):  
Tomáš Vopát ◽  
Jozef Peterka ◽  
Vladimír Šimna ◽  
Ivan Buranský
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Tool Material ◽  
High Speed Steel ◽  
Depth Of Cut ◽  
Radial Depth ◽  
End Mills

The article deals with the tool life of ball nose end mills and surface roughness of steel C45 depending on up-copying and down-copying. The cemented carbide and high speed steel was used as tool material. Furthermore, the new and sharpened cutting tools were also compared. In the experiment, the cutting speed, feed rate, axial and radial depth of cut were not changed. The results show different achieved surface roughness of machined material C45 and tool life of ball nose end mills depending on the copy milling strategy for various tool materials.

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