scholarly journals Additive surface texturing of cutting tools using pulsed laser implantation with hard ceramic particles

2020 ◽  
Vol 14 (5-6) ◽  
pp. 733-742
Author(s):  
S. Böhm ◽  
A. Ahsan ◽  
J. Kröger ◽  
J. Witte
Keyword(s):  
Flank Wear ◽  
Cutting Tools ◽  
Surface Texturing ◽  
Pulsed Laser ◽  
Ductile Cast Iron ◽  
Surface Structures ◽  
Rake Face ◽  
Dry Cutting ◽  
Ceramic Particles ◽  
Flank Face

AbstractIn recent years surface texturing of the cutting tools has proved to improve tribological characteristics at tool/chip and tool/workpiece interface and help to reduce cutting and feed forces as well as tool wear. Most, if not all, of the studies have focused on subtractively made textures whereby the material is removed from the surface. This study investigates the performance of additively made surface structures whereby hard ceramic particles are dispersed in the form of dome shaped textures on the surface of the cutting tools using solid state millisecond pulsed laser (pulsed laser implantation). Dry cutting tests were performed on ductile cast iron. The results show a greater reduction of process forces with implantation of flank face as compared to rake face. Both cutting and feed forces were reduced by 10% compared to the non-structured tool. In addition, the tool life increased by a factor of 3 whereas the average flank wear reduced by as much as 80% and cutting edge rounding by up to 60%.

scholarly journals Performance of Volcano-Like Laser Textured Cutting Tools: An Experimental and Simulative Investigation

Lubricants ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 98 ◽  
Author(s):  
Zhengyang Kang ◽  
Yonghong Fu ◽  
Xingyu Fu ◽  
Martin Jun
Keyword(s):  
Cutting Force ◽  
Cutting Tools ◽  
Surface Texturing ◽  
Temperature Fields ◽  
Small Scale ◽  
Rake Face ◽  
Forming Process ◽  
Force Reduction ◽  
And Performance ◽  
Distribution Of Stress

In recent years, surface texturing in micro-scale has been attempted on the surface of cutting tools for multiple purposes, e.g., cutting force reduction, prolonging life-span, anti-adhesion, etc. With respect to machinability and performance, micro-groove texture (MGT) has dominated in this field compared to other textured patterns. In this study, a novel volcano-like texture (VLT) was fabricated on the rake face of cemented carbide inserts (WC-Co, YG6) by fiber laser. The following cutting experiment tested the flat, MGT and VLT tools in turning aluminum alloy 6061. The effects of coolant and cutting conditions were investigated. In addition, a validated FEM model was employed to explore the distribution of stress and temperature fields in the tool-chip interface. The initial forming process of adhesion layer on rake face was investigated as well. The results indicated that lower cutting force and less adhesion can be achieved by small scale VLT. This study not only introduced VLT on cutting tools but also revealed its comprehensive performance.

Experimental Study of Tool Wear during Quasi High Speed Turning Titanium Alloy with Large Cutting Depth

2014 ◽  
Vol 800-801 ◽  
pp. 548-552
Author(s):  
Li Fu Xu ◽  
Wei Liang Dong ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Data ◽  
Titanium Alloy ◽  
High Speed ◽  
Flank Wear ◽  
Rake Face ◽  
Cutting Depth ◽  
Tool Flank Wear ◽  
High Speed Turning ◽  
Flank Face ◽  
Cutting Speeds

The wear morphology of rake face and flank face of tool is investigated by turning titanium alloy TC4 with CBN solid tool. It has been observed that the main wear form of rake face and flank face of tool is groove wear. The relation between tool flank wear and cutting speeds, feed rate, and cutting depth obtained from experimental data is given.

scholarly journals Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

Coatings ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1259
Author(s):  
Emre Altas ◽  
Hasan Gokkaya ◽  
Meltem Altin Karatas ◽  
Dervis Ozkan
Keyword(s):  
Surface Roughness ◽  
Shape Memory Alloy ◽  
Shape Memory ◽  
Flank Wear ◽  
Cutting Tools ◽  
Dominant Factor ◽  
Niti Shape Memory Alloy ◽  
Machining Parameters ◽  
Nose Radius ◽  
Dry Cutting

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

Research on Wear Property of Tool Flank by Dry Cutting of Austempering Ductile Iron

2011 ◽  
Vol 188 ◽  
pp. 38-42
Author(s):  
Dong Dong Wan ◽  
Xu Hong Guo ◽  
Chi Hong Wang
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Wear Property ◽  
Dry Cutting ◽  
Quenching Temperature ◽  
Tool Flank Wear ◽  
Heat Treated

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.

Experimental Study on the Cutting Performance of TiC-Based Nanocomposite Ceramic Tools in Turning 40Cr Steel

2011 ◽  
Vol 325 ◽  
pp. 309-314
Author(s):  
Han Lian Liu ◽  
Ming Hong ◽  
Chuan Zhen Huang ◽  
Bin Zou
Keyword(s):  
Flank Wear ◽  
Adhesive Wear ◽  
Cutting Tools ◽  
Cutting Performance ◽  
Rake Face ◽  
Ceramic Tool ◽  
Tool Materials ◽  
Ceramic Tools ◽  
Multi Scale ◽  
40Cr Steel

TiC-based ceramic cutting tools with three different particle size levels of Al2O3 additives were fabricated and tested. Theses tool materials were identified as TA, TA10A5 and TA30A5 respectively in this study. Another commercial cutting material identified as LT55 was used in this study as baseline to investigate cutting performance by comparing the flank wear size. The experimental results showed that multi-scale nanocomposite ceramic tool TA10A5 had much better wear resistance than the other tools when turning at a lower speed. The wear mechanisms were mainly adhesive wear in the rake face. While cutting at a higher speed, the breakage failure occurred for the tools TA10A5 and TA30A5.

Experimental Assessment of Laser Textured Cutting Tools in Dry Cutting of Aluminum Alloys

2016 ◽  
Vol 138 (7) ◽  
Author(s):  
Youqiang Xing ◽  
Jianxin Deng ◽  
Xingsheng Wang ◽  
Kornel Ehmann ◽  
Jian Cao
Keyword(s):  
Aluminum Alloys ◽  
Cutting Tools ◽  
Chip Morphology ◽  
Cutting Performance ◽  
Rake Face ◽  
Dry Cutting ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Chip Compression Ratio ◽  
Cemented Carbide Tools

To improve the friction conditions and reduce adhesion at the tool's rake face in dry cutting of aluminum alloys, three types of laser surface textures were generated on the rake face of cemented carbide tools. Orthogonal dry cutting tests on 6061 aluminum alloy tubes were carried out with the textured and conventional tools (CT). The effect of the texture geometry on the cutting performance was assessed in terms of cutting forces, friction coefficient, chip compression ratio, shear angle, tool adhesions, chip morphology, and machined surface quality. The results show that the textured tools can improve the cutting performance at low cutting speeds, and that the tool with rectangular type of textures is the most effective.

Wear Mechanisms of PCBN Cutting Tools in Hard and Dry Cutting GCr15 Bearing Steel

2011 ◽  
Vol 197-198 ◽  
pp. 1494-1499
Author(s):  
Rui Ping Liu ◽  
Fu Ming Deng ◽  
Xue Jun Lu
Keyword(s):  
Phase Transition ◽  
Tool Wear ◽  
Wear Mechanisms ◽  
Joint Action ◽  
Cutting Tools ◽  
Bearing Steel ◽  
Element Distribution ◽  
Dry Cutting ◽  
Gcr15 Bearing Steel ◽  
Flank Face

GCr15 bearing steel was turned with PCBN cutting tools in a manner of hard and dry cutting, and the characteristics and morphology of rake and flank face of PCBN cutting tools were observed, the element distribution of different regions of rake and flank face of PCBN cutting tools were tested and analyzed by use of EDS, and finally the wear mechanisms of PCBN cutting tools were discussed. The results showed that the wear areas of rake and flank face of PCBN cutting tools were small and mostly concentrated near the tip and sub-chamfering, and the reason was mechanical, oxidation, chemical and phase transition wear, which resulted in the joint action of tool wear.

Edge Sharpening and Surface Modification of PcBN Cutting Tool by Pulsed Laser Grinding

2012 ◽  
Vol 523-524 ◽  
pp. 131-136 ◽  
Author(s):  
Daisuke Suzuki ◽  
Fumihiro Itoigawa ◽  
Keiich Kawata ◽  
Tetsuro Suganuma ◽  
Takashi Nakamura
Keyword(s):  
Surface Modification ◽  
High Precision ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Pulsed Laser ◽  
Tool Material ◽  
Lateral Force ◽  
Hardened Steel ◽  
Rake Face ◽  
Diamond Grinding

PcBN cutting tools have excellent characteristics such as high degree of hardness and low chemical reactivity, so they have potential to replace high precision grinding of hardened steel with high precision cutting. PcBN might be more efficient tool material if improvement in formability, and good surface modification can be achieved. In order to solve these problems, Pulsed Laser Grinding (PLG) is applied to a shape cutting edge and to finish a rake face. After processing by the PLG, shaped cutting edges were observed with a scanning electron microscope (SEM) and measured with contact- type profilometer. As a result, cutting edges processed by the PLG are similar or shaper than that by conventional diamond grinding. In addition, as a one of effects of surface modification, The Vickers microhardness of rake faces increases by about 10 present after PLG. On the other hand, according to frictional test with lateral force microscopy, the coefficient of friction of rake face decreases by half of ordinary surface. Depending on these advantages of PLG, high precision turning of hardened steel with 58HRC in hardness by use of the tool processed by PLG can demonstrate good performance rather than a commercial tool with diamond grinding finish.

On the Measurement and Propagation of Flank Wear in Cutting Tools

1979 ◽  
Vol 101 (2) ◽  
pp. 109-115 ◽  
Author(s):  
M. M. Tseng ◽  
R. A. Noujaim
Keyword(s):  
Adaptive Control ◽  
Tool Wear ◽  
Tool Life ◽  
Conversion Factor ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
No Conversion ◽  
Flank Face

More than three hundred flank wear profiles of carbide cutting tools were digitized, stored and analyzed. It was found that different measures of the same wear zone, such as averages or maximums including or excluding the grooves, can significantly change the out-come of tool life studies. For a given test, all the measures used in this study correlate strongly with the true overall wear average during the entire tool life. However, no conversion factor independent of cutting conditions could be found for these measures. Propagation of tool wear profiles was also analyzed. It revealed that aside from the groove zones, the entire flank face shows equal significance in describing tool wear. Thus, when a wear sensor is physically embedded on the flank face for adaptive control purposes, any location between the grooves is as good as any other.

Study of the effect of surface laser texture on tribological properties of cemented carbide materials

2020 ◽  
Vol 234 (6-7) ◽  
pp. 993-1006
Author(s):  
Na Zhang ◽  
Fazhan Yang ◽  
Fulin Jiang ◽  
Guohua Liu
Keyword(s):  
Titanium Alloy ◽  
Friction Coefficient ◽  
Cutting Tools ◽  
Surface Texturing ◽  
Potential Method ◽  
Cemented Carbide ◽  
Textured Surface ◽  
Low Friction ◽  
Dry Cutting ◽  
Groove Texture

Surface texturing has become a potential method to obtain a low friction coefficient under dry/lubricated conditions for different mechanical product surfaces. The mechanism of friction and wear reduction from a micro-texture on the surface of cemented carbide cutting tools was investigated by dry cutting a titanium alloy. Three kinds of micro-textures, namely, line, sinusoidal and rhombic grooves, with different area occupancy rates were produced by a laser on the cemented carbide surface. Experiments and finite element simulation of ABAQUS were used to investigate the tribological characteristics of micro-textured cemented carbide. The results indicated that the line-textured cemented carbide with an area occupancy rate of 10% showed a low friction coefficient of 0.076, which is approximately 34% of the non-textured sample. Few adhesives appeared on the textured surface, while a large number of adhesives were attached to the smooth surface after 30 min of dry friction between the cemented carbide and the titanium alloy balls. Moreover, among the three textures, the line-groove texture has the smallest friction coefficient and a good anti-wear effect. The results show that the existence of a groove texture can effectively reserve the wear debris, reduce the bond wear and weaken the furrow effect.

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