Emitted Sound Amplitude Analysis Using Hilbert Huang Transformation for Cutting Tool Flank Wear Prediction

Three different cutting tools (ceramics CC6050, cubic boron nitride CB7025, carbide GC2025) were used for dry cutting of 3 groups of ADI which were heat-treated separately under different quenching temperatures. With the unified cutting parameters, the wear of tool flank of each cutter was studied and the main influencing factors of the wear were analyzed. Results showed that when the cutting parameters ap =0.2mm, f =0.16mm/r, vc =108m/min and the cutting tool was determined, the higher the quenching temperature was the lower the hardness of the test bars were and the tool flank wear was less; When the quenching temperature was determined, the more the produced BUE (build up edge) of the cutting tool was the less the tool flank wear was.

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Characterizations of cutting tool flank wear-land contact

Wear ◽

10.1016/j.wear.2007.01.080 ◽

2007 ◽

Vol 263 (7-12) ◽

pp. 1454-1458 ◽

Cited By ~ 25

Author(s):

Jianwen Hu ◽

Y. Kevin Chou

Keyword(s):

Cutting Tool ◽

Flank Wear ◽

Tool Flank Wear

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Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

Journal of Advanced Manufacturing Systems ◽

10.1142/s0219686717500159 ◽

2017 ◽

Vol 16 (03) ◽

pp. 237-261 ◽

Cited By ~ 3

Author(s):

T. Sampath Kumar ◽

S. Balasivanandha Prabu ◽

T. Sorna Kumar

Keyword(s):

Surface Roughness ◽

Alloy Steel ◽

Surface Finish ◽

Cutting Tool ◽

Flank Wear ◽

Cutting Tools ◽

Cutting Speed ◽

Depth Of Cut ◽

Tool Flank Wear ◽

Coated Carbide

In the present work, the performances of TiAlN-, AlCrN- and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN- and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi’s approach is used to obtain the best turning parameters, namely cutting speed ([Formula: see text]), feed rate ([Formula: see text]) and depth of cut ([Formula: see text]), in order to have a better surface finish and minimum tool flank wear. An orthogonal array (L[Formula: see text] was used to conduct the experiments. The results show that the AlCrN/TiAlN-coated cutting tool provided a much better surface finish and minimum tool flank wear. The minimum tool flank wear and minimum surface roughness were obtained using AlCrN/TiAlN-coated tools, when [Formula: see text][Formula: see text]m/min, [Formula: see text][Formula: see text]mm/rev and [Formula: see text][Formula: see text]mm.

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Effect of Tool Flank Wear on the Orthogonal Cutting Process

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.329.705 ◽

2007 ◽

Vol 329 ◽

pp. 705-710 ◽

Cited By ~ 6

Author(s):

X.L. Zhao ◽

Yong Tang ◽

Wen Jun Deng ◽

F.Y. Zhang

Keyword(s):

Cutting Forces ◽

Cutting Tool ◽

Flank Wear ◽

Orthogonal Cutting ◽

Cutting Temperature ◽

Element Model ◽

Cutting Process ◽

Temperature Fields ◽

Tool Flank Wear ◽

Chip Separation

A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.

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The influence of ultrasonic elliptical vibration amplitude on cutting tool flank wear

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405420929782 ◽

2020 ◽

Vol 234 (12) ◽

pp. 1499-1512 ◽

Cited By ~ 3

Author(s):

Mohsen Khajehzadeh ◽

Omid Boostanipour ◽

Soheil Amiri ◽

Mohammad Reza Razfar

Keyword(s):

Wear Mechanism ◽

Vibration Amplitude ◽

Cutting Tool ◽

Flank Wear ◽

Ultrasonic Vibrations ◽

Tool Flank Wear ◽

Elliptical Vibration ◽

Diffusion Wear ◽

Ultrasonic Assisted ◽

Ultrasonic Elliptical Vibration

In this article, the effect of vibration amplitude during ultrasonic elliptical vibration–assisted turning on cutting tool flank wear ( VBmax) and tool diffusion wear mechanism has been experimentally studied in machining of AISI 4140 hardened steel. To achieve this goal, an ultrasonic elliptical vibration–assisted turning setup was designed and manufactured. This device was then used in both ultrasonic-assisted tuning and ultrasonic elliptical vibration–assisted turning tests (i.e. one-dimensional and two-dimensional ultrasonic-assisted machining). According to the achieved results, ultrasonic elliptical vibration–assisted turning is more effective than ultrasonic-assisted tuning in reducing tool flank wear; at an amplitude of 13 μm, work velocity of 180 mm/s and feed of 0.09 mm/rev, VBmax were decreased 30.3% and 54.3%, respectively, in case of ultrasonic-assisted tuning and ultrasonic elliptical vibration–assisted turning. It was also observed that increasing the amplitude of ultrasonic vibrations reduces VBmax; at work velocity of 180 mm/s and feed of 0.09 mm/rev, the reduction of VBmax in ultrasonic elliptical vibration–assisted turning with amplitudes of 5 and 13 μm is, respectively, 39.3% and 54.3%, compared with that of conventional machining. The results also show that the application of ultrasonic vibrations weakens the cutting tool diffusion wear mechanism. This attenuation is much higher for ultrasonic elliptical vibration–assisted turning in comparison to ultrasonic-assisted tuning. Besides, the amount of attenuation in cutting tool diffusion wear mechanism decreases with increasing vibration amplitude.

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

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405416640416 ◽

2016 ◽

Vol 233 (5) ◽

pp. 1472-1482 ◽

Cited By ~ 2

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.

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Comparative study of flank wear, tool life and type of chips for two similar turning inserts from different producers

MATEC Web of Conferences ◽

10.1051/matecconf/201824402008 ◽

2018 ◽

Vol 244 ◽

pp. 02008

Author(s):

Karel Šramhauser ◽

Nataša Náprstková ◽

Pavel Kraus ◽

Martin Marek

Keyword(s):

Stainless Steel ◽

Comparative Study ◽

Stainless Steels ◽

Cutting Tool ◽

Flank Wear ◽

Critical Value ◽

Tool Flank Wear ◽

Cutting Inserts ◽

Wear Tool ◽

Cutting Speeds

The article describes the analysis of the durability and lifetime of selected interchangeable cutting inserts used for turning based on the wear measurement of the cutting tool, flank wear namely. The experiment was carried out on one type of material, such as stainless steel 1.4404 according to DIN EN 10088-3. The measurements were made on two turning inserts of the same type from two different manufacturers - Sandvik coromant and Pramet tools. Evaluation of turning inserts wear was performed at four different cutting speeds. The value that was observed was the flank wear VB of the tool until the critical value was reached. Other different analysis have been performed, such as the length and shape of the chips analysis according to ISO 3685. Based on the results of the measurements, it has been found that the Pramet insert, which has a thinner layer of coating, has reached a longer life and allows heat to flow out of the cutting area. It can be considered that thinner coating can positively contribute to better machining of stainless steels, which could be helpful for machining companies. Cutting inserts wear research is realized at the Faculty of Mechanical Engineering of Jan Evangelista Purkyně University in Ústí nad Labem.

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