Tool life of nanocomposite Ti–Al–Si–N coated end-mill by hybrid coating system in high speed machining of hardened AISI D2 steel

The application of Titanium alloys are increasingly seen at aerospace, marine, bio-medical and precision engineering due to its high strength to weight ratio and high temperature properties. However while machining the titanium alloys using solid carbide tools, even with jet infusion of coolant lower tool life was vividly seen. The high temperatures generated at the tool-work interface causes adhesion of work-material on the cutting edges and hence shorter tool life was reported. To reduce the high tool work interface temperature positive rake angle, higher primary relief and higher secondary relief were configured on the ball nose end-mill cutting edges. However after a initial working period the growth of flank wear facilitates higher cutting forces followed by work-material adhesion on the cutting edges. Therefore it is important to blend the: strength, sharpness, geometry and surface integrity on the cutting edges so that the ball nose end mill would demonstrate an extended tool-life. This paper illustrates the effect of ball nose end mill geometry on high speed machining of Ti6Al4V. Three different ball nose end mill geometries were configured and high speed machining experiments were conducted to study the influence of tool geometry on the metal cutting mechanism of Ti-6Al-4V alloy. The high speed machining results predominantly emphasize the significance of cutting edge features such as: K-Land, rake angle and cutting edge radius. The ball nose end-mills featured with a short negative rake angle of value −5° for 0.05–0.06 mm i.e., K-Land followed by positive rake angle of value 8° has produced lower cutting forces signatures for Ti-6Al-4V alloy.

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Multi-Objective Optimization of Process Parameters in Pack Siliconizing on AISI D2 Steel

Silicon ◽

10.1007/s12633-020-00735-4 ◽

2020 ◽

Author(s):

Mojtaba Najafizadeh ◽

Mehran Ghasempour-Mouziraji

Keyword(s):

Process Parameters ◽

Multi Objective Optimization ◽

Aisi D2 Steel ◽

Multi Objective ◽

Optimization Of Process Parameters ◽

Aisi D2 ◽

D2 Steel

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Highlights of the DARPA Advanced Machining Research Program

Journal of Engineering for Industry ◽

10.1115/1.3186005 ◽

1985 ◽

Vol 107 (4) ◽

pp. 325-335 ◽

Cited By ~ 40

Author(s):

R. Komanduri ◽

D. G. Flom ◽

M. Lee

Keyword(s):

Thermal Properties ◽

Tool Wear ◽

Titanium Alloys ◽

Tool Life ◽

Research Program ◽

High Speed ◽

Metal Removal ◽

High Speed Machining ◽

Advanced Machining ◽

Nickel Base

Results of a four-year Advanced Machining Research Program (AMRP) to provide a science base for faster metal removal through high-speed machining (HSM), high-throughput machining (HTM) and laser-assisted machining (LAM) are presented. Emphasis was placed on turning and milling of aluminum-, nickel-base-, titanium-, and ferrous alloys. Experimental cutting speeds ranged from 0.0013 smm (0.004 sfpm) to 24,500 smm (80,000 sfpm). Chip formation in HSM is found to be associated with the formation of either a continuous, ribbon-like chip or a segmental (or shear-localized) chip. The former is favored by good thermal properties, low hardness, and fcc/bcc crystal structures, e.g., aluminum alloys and soft carbon steels, while the latter is favored by poor thermal properties, hcp structure, and high hardness, e.g., titanium alloys, nickel base superalloys, and hardened alloy steels. Mathematical models were developed to describe the primary features of chip formation in HSM. At ultra-high speed machining (UHSM) speeds, chip type does not change with speed nor does tool wear. However, at even moderately high speeds, tool wear is still the limiting factor when machining titanium alloys, superalloys, and special steels. Tool life and productivity can be increased significantly for special applications using two novel cutting tool concepts – ledge and rotary. With ledge inserts, titanium alloys can be machined (turning and face milling) five times faster than conventional, with long tool life (~ 30 min) and cost savings up to 78 percent. A stiffened rotary tool has yielded a tool life improvement of twenty times in turning Inconel 718 and about six times when machining titanium 6A1-4V. Significantly increased metal removal rates (up to 50 in.3/min on Inconel 718 and Ti 6A1-4V) have been achieved on a rigid, high-power precision lathe. Continuous wave CO2 LAM, though conceptually feasible, limits the opportunities to manufacture DOD components due to poor adsorption (~ 10 percent) together with high capital equipment and operating costs. Pulse LAM shows greater promise, especially if new laser source concepts such as face pump lasers are considered. Economic modeling has enabled assessment of HSM and LAM developments. Aluminum HSM has been demonstrated in a production environment and substantial payoffs are indicated in airframe applications.

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Evaluation of Deep Criogenic Treatment at Microabrasive Wear of Aisi D2 Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1120-1121.1257 ◽

2015 ◽

Vol 1120-1121 ◽

pp. 1257-1263

Author(s):

Cosme Roberto Moreira Silva ◽

Tiago F.O. Melo ◽

José A. Araújo ◽

J.L.A. Ferreira ◽

S.J. Gobbi

Keyword(s):

Wear Resistance ◽

Treatment Cycle ◽

Cryogenic Treatment ◽

Deep Cryogenic Treatment ◽

Abrasive Resistance ◽

Austenitization Temperature ◽

Aisi D2 Steel ◽

X Ray ◽

Aisi D2 ◽

D2 Steel

Wear resistance of tool steels can be increased with deep cryogenic treatment (DCT) application. Mechanisms related to DCT are still not completely understood. Microabrasive wear resistance of cryogenically treated samples of AISI D2 steel was evaluated in terms of austenitization temperature at heat treatment cycle and quenching steps related to DCT. X-ray difractometry, scanning and optical microscopy and quantitative evaluation of carbides with image analysis were carried out aiming material characterization. For samples subjected to higher austenitization temperatures, the DCT treatment does not increase abrasive wear resistance. For samples treated at lower austenitization temperature, the DCT treatment results on 44% increase at abrasive resistance. This effect is correlated to the increase of the amount of fine carbides distributed at samples matrices cryogenically treated.

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A comparative study in machining of AISI D2 steel using textured and non-textured coated carbide tool at the flank face

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2018.10.041 ◽

2018 ◽

Vol 36 ◽

pp. 360-372 ◽

Cited By ~ 7

Author(s):

Sanjib Kr Rajbongshi ◽

Meinam Annebushan Singh ◽

Deba Kumar Sarma

Keyword(s):

Comparative Study ◽

Carbide Tool ◽

Aisi D2 Steel ◽

Coated Carbide Tool ◽

Aisi D2 ◽

Flank Face ◽

Coated Carbide ◽

D2 Steel

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Sustainable machining. Modeling and optimization of temperature and surface roughness in the milling of AISI D2 steel

Industrial Lubrication and Tribology ◽

10.1108/ilt-11-2017-0322 ◽

2019 ◽

Vol 71 (2) ◽

pp. 267-277 ◽

Cited By ~ 14

Author(s):

Aqib Mashood Khan ◽

Muhammad Jamil ◽

Ahsan Ul Haq ◽

Salman Hussain ◽

Longhui Meng ◽

...

Keyword(s):

Surface Roughness ◽

Process Parameters ◽

Empirical Modeling ◽

Cutting Fluid ◽

Depth Of Cut ◽

Aisi D2 Steel ◽

Content Type ◽

Sustainable Machining ◽

Aisi D2 ◽

D2 Steel

Purpose Sustainable machining is a global consensus and the necessity to cope up the serious environmental threats. Minimum quantity lubrication (MQL) and nanofluids-based MQL(NFMQL) are state-of-the-art sustainable lubrication modes. The purpose of this study is to investigate the effect of process parameters, such as feed rate, depth of cut and cutting fluid flow rate, on temperature and surface roughness of the manufactured pieces during face milling of the AISI D2 steel. Design/methodology/approach A statistical technique called response surface methodology with Box–Behnken Design was used to design experimental runs, and empirical modeling was presented. Analysis of variance was carried out to evaluate the model’s accuracy and the validation of the applied technique. Findings A comprehensive analysis revealed the superiority of implementing NFMQL in comparison to MQL within the levels of process parameters. The comparison has shown a significant reduction of temperature under NFMQL at the tool-workpiece interface from 16.2 to 34.5 per cent and surface roughness from 11.3 to 12 per cent. Practical implications This research is useful for practitioners to predict the responses in workshop and select appropriate cutting parameters. Moreover, this research will be helpful to reduce the resource which will ultimately save energy consumption and cost. Originality/value To cope with the industrial challenges and tribological issues associated with the milling of AISI D2 steel, experiments were conducted in a distinct machining mode with innovative cooling/lubrication. Until now, few studies have addressed the key lubrication effects of Al2O3-based nanofluid on the machinability of D2 steel under NFMQL lubrication condition.

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