A Comparative Experimental Study on Machining Performance of Aluminium against Advanced Diamond Coated Cutting Tool Inserts

Carbide tools with mono/multilayer coating such as TiN, TiC, TiAIN, TiB2 and Al2O3 on inserts of WC-Co generated key success for machining of ferrous materials without coolant/lubrication. So far dry machining of aluminium, manufacturing industries such as automobile and aerospace engineering are facing considerable challenges. Exploration of correct cutting tool for machining of aluminium still persists in the present day context. This paper experimentally investigated the affinity and performance of different cutting tool materials available in local tool shopping center along with the diamond coated tool insert prepared and developed in our own HFCVD reactor for machining of aluminium in dry condition. Finally it is revealed that, due to the low chemical affinity, small magnitude of cutting force, chemical inertness and remarkable anti-welding characteristics, diamond coated tool displayed improved performance as compared to other tools.

Suitability of natural rocks as materials for cutting tools

This study presents an investigation of the usability and suitability of natural rocks as cutting tool materials. Therefore, indexable inserts are manufactured from eight different rocks and two mono minerals in this study and are used for turning of an aluminium alloy. Besides that, a characterization of the rock properties is performed. The wear of the rock tools and the surface roughness of the workpiece generated by the tools are used to evaluate their operational behaviour. Subsequently, the rock properties and the corresponding operational behaviour are used to assess the suitability of the rocks as cutting tool material. The results show that rock inserts can be used as cutting material for the turning of an aluminium alloy showing a width of wear marks between 83 and 1665 µm at the flank face after a cutting length of 500 m depending on the rock used. Furthermore, it is shown that rock tools are able to achieve surface roughness values which are comparable to those obtainable by using a conventional cemented carbide insert. The study shows that natural rocks can generally be used as alternative cutting material for the turning of aluminium. In addition a possible way for a systematic investigation and assessment of the suitability of natural rocks as cutting tool materials is presented, the relevance of the rock properties for the operational behaviour of the rock inserts is described and relevant future research topics concerning the use of rocks as cutting tool material are identified. Article highlights Demonstrating the possibility to use natural rocks as alternative environmentally friendly cutting tool material. Evaluation of operational behaviour and wear mechanisms of rock tools in turning aluminium. Identification of rock properties relevant for the operational behaviour of rock inserts.

Some Aspects of Damage Management for Cutting Tool Materials

There are two concepts in the title that can be seen as “foreign” to the usual technical language. Both can have several meanings and thus we adapted them “flexibly” to the current needs. One way to understand the term “management” is through its functions: planning (defining purpose and means), organizing (defining tasks and methods), and direction (guidance, controlling), inspection (testing, comparing). It can also mean among other things, standpoint, circumstance, respect, or even character. Regarding the expression “damage management” the intended meaning here is reducing or to preventing damage to the tool, also improving the resistance of the tool material to damage, which besides material selection issues also has design, technology and operational aspects. This article gives an overview of some of these.