Types of Tool Wear of AlTiN Coated Cutting Insert after Machining of Weld Overlay

2017 ◽  
Vol 261 ◽  
pp. 237-242
Author(s):  
Daniel Kottfer ◽  
Ildikó Maňková ◽  
Marek Vrabel' ◽  
Marta Kianicová ◽  
František Rehák ◽  
...  
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Optical Microscope ◽  
Cutting Edge ◽  
Weld Overlay ◽  
Different Types ◽  
Cutting Insert ◽  
Rough Turning

Authors of the paper present different types of tool wear after machining of weld overlay with AlTiN cutting insert. Welded layer was created on roller made from S355J0 steel by Open Arc (OA) method also referred as Metal One Gas (MOG). Various forms of tool wear were documented by optical microscope. Microchipping of cutting edge, built up edge (BUE) and flank wear were identified on examined round insert in rough turning of hard cladding.

Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 2: Effect of tool failure modes

2015 ◽  
Vol 231 (9) ◽  
pp. 1575-1586 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Machined Surface ◽  
Tool Failure ◽  
Geometric Ratio ◽  
Cutting Speeds

Variation in the geometric and surface features of segmented chips with an increase in the volume of material removed and tool wear has been investigated at cutting speeds of 150 and 220 m/min at which the cutting tools fail due to gradual flank wear and plastic deformation of the cutting edge, respectively. Among the investigated geometric variables of the segmented chips, slipping angle, undeformed surface length, segment spacing, degree of segmentation and chip width showed the different variation trends with an increase in the volume of material removed or flank wear width, and achieved different values when tool failed at different cutting speeds. However, the chip geometric ratio showed a similar variation trend with an increase in the volume of material removed and flank wear width, and achieved the similar value at the end of tool lives at cutting speeds of both 150 and 220 m/min regardless of the different tool failure modes. Plastic deformation of the tool cutting edge results in severe damage on the machined surface of the chip and significant compression deformation on the undeformed surface of the chip.

Edge Preparation on Cutting Force, Cutting Temperature and Tool Wear for Hard Turning

2014 ◽  
Vol 800-801 ◽  
pp. 424-429
Author(s):  
Pei Rong Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Crater Wear ◽  
Cutting Edge Preparation ◽  
Flank Face ◽  
Edge Preparation

The paper investigates the effects of cutting edge preparation on cutting force, cutting temperature and tool wear for hard turning. An optimized characterization approach is proposed and five kinds of cemented tools with different edge preparation are adopted in the simulations by DEFROM-2DTM. The results show that both the forces and cutting temperature on the rake face climb up and then declines with the increasing of factor K (Sγ/Sα). While the temperature on flank face decrease with the increasing of the factor K. When the cutting conditions are identical, flank wear reduces while crater wear exacerbates before easing with the increasing of the factor K. The simulation results will provide valuable suggestions for optimization of cutting edge preparation for hard turning in order to obtain excellent machining quality and longer tool life.

Optimal flank wear in turning of Inconel 625 super-alloy using ceramic tool

2016 ◽  
Vol 232 (2) ◽  
pp. 208-216 ◽  
Author(s):  
M Jahanbakhsh ◽  
A Akhavan Farid ◽  
Mohammad Lotfi
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Flank Wear ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Cutting Condition

Rapid tool wear is one of the major machinability aspects of nickel-based super alloys. In this article, the effect of cutting parameters on material removal rate and tool wear of a whisker ceramic insert in turning of Inconel 625 was examined. Optical microscope and scanning electron microscope were applied to measure and study tool wear mechanism. Response surface method was used to develop a mathematical model which confirmed by experimental tests. The statistical analysis done by analysis of variance showed that depth of cut is the most effective factor on the tool wear. Experiments showed that increment of feed rate had an insignificant effect on the progress of flank wear, and it is an important controlling factor when material removal rate is considered as a desired output. Finally, optimized cutting condition is presented in this work.

Effect of cutting edge geometry change due to tool wear on hole quality in drilling of carbon fiber reinforced plastics using advanced ceramic coated tools

2021 ◽  
pp. 095440622110235
Author(s):  
Mohammad Sayem Bin Abdullah ◽  
Dave Kim ◽  
Patrick Kwon ◽  
Tae-Gon Kim
Keyword(s):  
Carbon Fiber ◽  
Tool Wear ◽  
Flank Wear ◽  
Cutting Edge ◽  
Fiber Reinforced ◽  
Hole Quality ◽  
Cutting Edge Radius ◽  
Edge Geometry ◽  
Edge Radius ◽  
Carbon Fiber Reinforced

This paper aims to study the evolution of cutting edge geometry due to tool wear and discuss its impact on the hole quality of a carbon fiber reinforced plastic (CFRP) laminate. A drilling experiment was conducted using three types of twist drills: uncoated, BAM (AlMgB14) coated, and (AlCrSi/Ti)N nanocomposite coated tungsten carbide tools. After generating 120 holes, the uncoated drill had the largest cutting edge radius (∼36 µm), while the BAM coated drill had the most extensive flank wear (∼287 µm) among the three drills. This relatively rapid tool wear results in a reduction of average hole size and a considerable variation on the hole profiles. The worn drills with the cutting edge radius greater than 19.3 µm form the fiber pull-outs in not only the 135° plies but also the adjacent 45° and 90° plies from the cutting direction, creating deep void networks. This type of networked fiber pull-out damage was observed with the holes machined by the uncoated and BAM coated drills. The (AlCrSi/Ti)N coated drill, which experienced the least amount of flank wear and the least increase of cutting edge radius, generated consistently sized holes up to 120 holes. However, the relatively sharp (AlCrSi/Ti)N coated tool results in the higher arithmetic roughness average (Ra) and the maximum roughness height (Rz) values than the other tools due to the localized fiber pull-outs and the absence of severe matrix smearing.

Investigation of the Relationship Between Vibration Data and Tool Wear During End-Milling of Gamma-Prime Strengthened Alloys

2015 ◽  
Author(s):  
Vasileios Bardis ◽  
Farbod Akhavan Niaki ◽  
Durul Ulutan ◽  
Laine Mears
Keyword(s):  
Tool Wear ◽  
Prediction Models ◽  
Flank Wear ◽  
End Milling ◽  
Optical Microscope ◽  
Condition Based Maintenance ◽  
Tool Flank Wear ◽  
Vibration Data ◽  
Gamma Prime ◽  
The Relationship

Condition Based Maintenance (CBM) systems are crucial for today’s high accuracy machining of exotic materials. For reliable results, CBM systems need early and reliable warning based on prediction models that use multiple types of sensors. In this study, tool flank wear during end milling difficult-to-machine alloys was measured using an optical microscope. Then, vibration data collected with an accelerometer was investigated for its relationship to tool flank wear. The developed relationship between accelerometer output and tool flank wear was validated with further experiments. It was observed from frequency domain responses of these outputs that specific harmonics of the tool pass frequency were dominant, and tool flank wear can be related to the amplitude of these harmonics during machining. This way, it was shown that through accurate online prediction of tool wear, premature interruption of the process as well as machining with a worn tool can both be avoided, improving end-product quality as well as reducing machining costs.

Combined effects of various materials on tool wear in drilling of Ti/CFRP stacks

2019 ◽  
Vol 234 (14) ◽  
pp. 2750-2759
Author(s):  
Qi Wang ◽  
Fuji Wang ◽  
Chong Zhang ◽  
Chen Chen
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Thrust Force ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Combined Effects ◽  
Wear Process ◽  
Drill Bits ◽  
Tool Performance ◽  
The Relationship

Ti/CFRP stacks present the key function in the aviation field due to their excellent properties. However, both titanium alloy and CFRP are hard-to-cut materials and their requirements on cutting tool performance are significantly different. When drilling Ti/CFRP stacks using a compromised tool, tool wear is affected by two materials, resulting in extremely low tool life. This paper investigates the wear process of chisel edge and main cutting edge of carbide step drill bits in the drilling of Ti/CFRP stacks, titanium alloys and CFRP, and the combined effects of various materials on the tool wear are revealed. Based on the wear analysis, it is found that tool wear is more affected by the carbon fiber/Ti-adhesion interaction which makes the rake face more susceptible to occur adhesive wear and slows down the flank wear, and severe rake wear and flank wear have a sharpening effect on cutting edge. It also reveals the relationship between thrust force and tool wear, and results indicate that the variation of thrust force is related to the flank wear and the Ti-adhesion attached to chisel edge, but not to the edge rounding. The conclusions reported in this paper can provide guidance for structural optimization of long-life stacks cutting tools.

Effect of cutting edge modification on the tool flank wear in ultrasonically assisted turning of hardened steel

2016 ◽  
Vol 233 (5) ◽  
pp. 1472-1482 ◽  
Author(s):  
Masoud Farahnakian ◽  
Mohamad Ebrahim Keshavarz ◽  
Sadegh Elhami ◽  
Mohammad Reza Razfar
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Edge ◽  
Machining Processes ◽  
Tool Flank Wear ◽  
Hardened Alloy ◽  
Hard Materials ◽  
Hard And Brittle Materials ◽  
Tungsten Carbide Tool

Ultrasonically assisted turning is one of the modern machining processes developed in recent decades to facilitate machining of hard-to-cut materials which are widely used in different industries. Cutting tool wear is one of the main problems in machining of hard materials which has necessitated implementation of modern machining processes such as ultrasonically assisted turning. Due to vibro-impact conditions, cutting tool failure takes place when ultrasonically assisted turning is applied for hard and brittle materials. In fact, microchipping takes place in the tool nose after machining of short length, so sharp cutting edge fails at the early stages of cutting. Therefore, if the sharpness of cutting edge is removed before the machining, the fracture of cutting edge, caused by vibro-impact condition, will be eliminated. The aim of this research is to investigate the tungsten carbide tool flank wear in ultrasonically assisted turning of hardened alloy steel in comparison to the conventional turning. Therefore, a proper experimental ultrasonic vibration configuration was designed to apply the ultrasonic vibrations to the turning tool along cutting direction. Experiments were carried out for different cutting speeds below the critical speed in ultrasonically assisted turning. Application of the tool with modified specifications led to make an initial wear on tool flank, but finally a significant improvement of tool wear was observed.

Experimental Study on Chip Shape and Tool Wear of High-Speed and Micro-Feed Cutting

2010 ◽  
Vol 431-432 ◽  
pp. 479-482
Author(s):  
Dao Chun Xu ◽  
Ping Fa Feng ◽  
Ding Wen Yu ◽  
Zhi Jun Wu
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Flank Wear ◽  
Chip Thickness ◽  
Friction Angle ◽  
Rake Angle ◽  
Cutting Edge ◽  
Effective Rake Angle ◽  
On Chip

With increasing spindle speed the cutting will be easy to enter into micro-feed cutting region. In the paper, the chip thickness and shape of high-speed and micro-feed cutting was researched in orthogonal milling. The cutting times in different fz was analyzed. We calculate the effective rake angle, friction angle and shear angle Furthermore, we measure cutting edge arc wear and tool flank wear of micro-feed cutting. Shown as the research results, the phenomenon of empty cutting and pure extrusion is very obvious as the feed rate per tooth is lower than 0.011mm/z. As the feed rate per tooth is lower than 0.005mm/z, the tool wear form is mainly cutting edge arc wear. As fz achieves 0.015mm/z, tool wear will decrease obviously and the tool appears the self-sharpening phenomenon.

Monitoring of Tool Wear Distribution With Cutting Force Measurement in Drilling

2020 ◽  
Author(s):  
Shoichi Tamura ◽  
Kodai Sekigawa ◽  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Normal Force ◽  
Flank Wear ◽  
Force Measurement ◽  
Cutting Edge ◽  
Drilling Process ◽  
Machining Processes ◽  
Tool Performance ◽  
Edge Damage

Abstract In the automated machining processes, tool damage should be managed to assure product qualities, promote machine tool performance and reduce production time and cost. In drilling process, the cutting process changes along the cutting edge; and the tool wear is not uniform. This paper presents a monitoring of the tool wear distribution with measuring the cutting force in drilling with a twist drill. The cutting force increases with the cutting area in the edge penetration into workpiece in drilling. In the proposed approach, the cutting edges are divided into small discrete segments. The increasing rate of the cutting force at a segment is associated with the normal forces loaded at the cutting area. The normal force distributions, then, are estimated for the cutting edge damage. The widths of flank wear lands along the cutting edge is monitored based on the increase of the normal force distribution. The cutting tests were conducted to validate the presented approach with measuring the cutting force in drilling of carbon steel. The presented approach estimates the tool wear distribution on the edge with the cutting time. The average stress distribution loaded on the flank wear land is also estimated in the regression analysis.

scholarly journals Investigation of the Wear Behavior of PVD Coated Carbide Tools during Ti6Al4V Machining with Intensive Built Up Edge Formation

Coatings ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 266
Author(s):  
M.S.I. Chowdhury ◽  
B. Bose ◽  
S. Rawal ◽  
G.S. Fox-Rabinovich ◽  
S.C. Veldhuis
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Wear Behavior ◽  
Cutting Temperature ◽  
Ti6al4v Alloy ◽  
Adhesive Interaction ◽  
Heavy Load ◽  
Micromechanical Properties ◽  
Rough Turning ◽  
Coated Carbide

Tool wear phenomena during the machining of titanium alloys are very complex. Severe adhesive interaction at the tool chip interface, especially at low cutting speeds, leads to intensive Built Up Edge (BUE) formation. Additionally, a high cutting temperature causes rapid wear in the carbide inserts due to the low thermal conductivity of titanium alloys. The current research studies the effect of AlTiN and CrN PVD coatings deposited on cutting tools during the rough turning of a Ti6Al4V alloy with severe BUE formation. Tool wear characteristics were evaluated in detail using a Scanning Electron Microscope (SEM) and volumetric wear measurements. Chip morphology analysis was conducted to assess the in situ tribological performance of the coatings. A high temperature–heavy load tribometer that mimics machining conditions was used to analyze the frictional behavior of the coatings. The micromechanical properties of the coatings were also investigated to gain a better understanding of the coating performance. It was demonstrated that the CrN coating possess unique micromechanical properties and tribological adaptive characteristics that minimize BUE formation and significantly improve tool performance during the machining of the Ti6Al4V alloy.

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