Cutting Performance of Ceramic Tools in Turning of Mild Steel

2012 ◽  
Vol 523-524 ◽  
pp. 493-496 ◽  
Author(s):  
Ryutaro Tanaka ◽  
Akira Hosokawa ◽  
Tatsuaki Furumoto ◽  
Takashi Ueda
Keyword(s):  
Mild Steel ◽  
Tool Life ◽  
Cutting Speed ◽  
Alumina Ceramic ◽  
Cutting Performance ◽  
The Other ◽  
Ceramic Tool ◽  
Ceramic Tools ◽  
Coated Carbide ◽  
Standard Steel

This study deals with the cutting performance of ceramic tools in turning of mild steel and BN free-machining steel based on it. The tool lives of ceramic tools in turning standard steel were less than 15 min at the cutting speed 250 m/min. On the other hand, the tool lives in turning of BN free-machining steel were obvious longer than that of standard steel. The tool life of TiC added alumina ceramic tool reached almost 10 hours in the case that the tool life criteria was set at VB=0.3mm. This tool life was twice as long as that of coated carbide tool.

Cutting Performance of TiB2/WC/h-BN Micro/nano Composite Gradient Self-Lubricating Ceramic Tool when Machining Carbon Steel

2014 ◽  
Vol 887-888 ◽  
pp. 1205-1209 ◽  
Author(s):  
Hui Chen ◽  
Chong Hai Xu ◽  
Xiu Guo Xu ◽  
Bin Fang ◽  
Guang Chun Xiao
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Adhesive Wear ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Cutting Performance ◽  
Ceramic Tool ◽  
Nano Composite ◽  
Cutting Experiments ◽  
Primary Pattern

Continuous cutting experiments of steel 45 were conducted to investigate cutting performance of TiB2/WC/h-BN micro/nano composite gradient self-lubricating ceramic tool. Influences of cutting speed on flank wear and tool life were analyzed. The results show that flank wear increases slightly when cutting speed V≥80 m/min, tool life increases initially and then decreases with increasing cutting speed. Wear mechanism was studied: the primary pattern of tool wear is abrasive wear and adhesive wear and solid-lubricants in tool have a noticeable wear-resistance effect during machining.

scholarly journals Roughing Milling with Ceramic Tools in Comparison with Sintered Carbide on Nickel-Based Alloys

Coatings ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 734
Author(s):  
Pablo Fernández-Lucio ◽  
Octavio Pereira Neto ◽  
Gaizka Gómez-Escudero ◽  
Francisco Javier Amigo Fuertes ◽  
Asier Fernández Valdivielso ◽  
...  
Keyword(s):  
Cutting Speed ◽  
High Volume ◽  
Cemented Carbide ◽  
Performance Ratio ◽  
Cost Performance ◽  
Ceramic Tools ◽  
The Cost ◽  
Engine Components ◽  
Coated Carbide ◽  
Milling Tools

Productivity in the manufacture of aircrafts components, especially engine components, must increase along with more sustainable conditions. Regarding machining, a solution is proposed to increase the cutting speed, but engines are made with very difficult-to-cut alloys. In this work, a comparison between two cutting tool materials, namely (a) cemented carbide and (b) SiAlON ceramics, for milling rough operations in Inconel® 718 in aged condition was carried out. Furthermore, both the influence of coatings in cemented carbide milling tools and the cutting speed in the ceramic tools were analysed. All tools were tested until the end of their useful life. The cost performance ratio was used to compare the productivity of the tested tools. Despite the results showing higher durability of the coated carbide tool, the ceramic tools presented a better behavior in terms of productivity at higher speed. Therefore, ceramic tools should be used for higher productivity demands, while coated carbide tools for low speed-high volume material removal.

Cutting Performance and Wear Mechanism of Si3N4-Based Nanocomposite Ceramic Tool

2010 ◽  
Vol 443 ◽  
pp. 324-329 ◽  
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Han Lian Liu ◽  
Jin Peng Song
Keyword(s):  
Wear Resistance ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Nano Particles ◽  
Ceramic Tool ◽  
Tool Materials ◽  
High Cutting Speed ◽  
The Matrix

Si3N4/TiN nanocomposite tool and Si3N4/Ti(C7N3) nanocomposite tool were prepared. The cutting performance and wear mechanism of Si3N4-based nanocomposite ceramic tool was investigated by comparison with a commercial sialon ceramic tool in machining of 45 steel. Si3N4-based nanocomposite ceramic tool exhibits the better wear resistance than sialon at the relatively high cutting speed. The increased cutting performance of Si3N4-based nanocomposite ceramic tool is ascribed to the higher mechanical properties. Nano-particles can refine the matrix grains and improve the bonding strength among the matrix grains of Si3N4-based nanocomposite ceramic tool materials. It contributes to an improved wear resistance of the cutting tools during machining.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

Study on Cutting Performance and Wear Mechanisms of Graded Ceramic Tool

2014 ◽  
Vol 490-491 ◽  
pp. 358-361
Author(s):  
Yan Zheng Li ◽  
Zhong De Shan ◽  
Jun Zhao ◽  
Jing Yun Xiong
Keyword(s):  
Ductile Iron ◽  
Wear Mechanisms ◽  
High Speed ◽  
Nickel Content ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Ceramic Tool ◽  
Dry Cutting ◽  
Short Segment ◽  
Graded Ceramic Tool

In this paper, based on the experiments of high speed dry cutting nickel alloyed ductile iron with different nickel contents by graded ceramic tool, the cutting performance and wear mechanisms of graded ceramic tool were investigated. Results reveal that with the increase of cutting speed and nickel content the wear of graded ceramic tool is increased, wear mechanisms are transformated spalling and cohesive wear from abrasive wear, and chip shapes are turned into long arc segment from short segment.

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

2010 ◽  
Vol 33 ◽  
pp. 173-176
Author(s):  
X.Y. Wang ◽  
S.Q. Pang ◽  
Q.X. Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Experimental Research ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Life Testing ◽  
Processing Efficiency ◽  
Comparative Tests ◽  
Coated Carbide ◽  
Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

Effect of Cutting Speed on Chipping and Wear of the SiAlON Ceramic Tool in Dry Finish Turning of the Precipitation Hardenable IN100 Aerospace Superalloy

2018 ◽  
Vol 141 (2) ◽  
Author(s):  
Mohamed A. Shalaby ◽  
Stephen C. Veldhuis
Keyword(s):  
Photoelectron Spectroscopy ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Ceramic Tool ◽  
Finish Turning ◽  
Ceramic Tools ◽  
Sialon Ceramic ◽  
Tool Edge ◽  
Chip Compression Ratio

Inconel 100 (IN100) aerospace superalloy is used in manufacturing aero-engine components that operate at intermediate temperatures. It is considered to be a hard-to-cut material. Chipping of the tool edge is one of the major failure mechanisms of ceramic tools in finish cutting of superalloys, which causes a sudden breakage of the cutting edge during machining. Cutting temperature significantly depends on cutting speed. Varying the cutting speed will affect the frictional action during the machining operations. However, proper selection of the cutting variables, especially the cutting speed, can prevent chipping occurrence. In this work, the influence of controlling the cutting speed on the chipping formation in dry finish turning of IN100 aerospace superalloy using SiAlON ceramic tool has been investigated. Scanning electron microscope (SEM)/energy dispersing spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), and three-dimensional wear measurements were used to make the investigations of the worn tool edges. It was found that variations of the cutting speeds in a certain range resulted in the generation of different lubricious and protective tribo-films. The presence of these tribo-films at the cutting region proved essential to prevent chipping of the cutting tool edge and to improve its wear resistance during finish turning of age-hardened IN 100 using SiAlON ceramic tools. Chip compression ratio and calculated values of the coefficient of friction at the tool–chip interface confirmed these results.

Experimental Study of Cutting Performance and Tool Wear in Dry Side Milling of Aluminum Alloy with DLC-Coated HSS-Co Cutter

2012 ◽  
Vol 523-524 ◽  
pp. 64-69
Author(s):  
Yoshio Mizugaki ◽  
Kazuki Takafuji ◽  
Koichi Kikkawa ◽  
Teppei Kuroda ◽  
Taro Kimura
Keyword(s):  
Aluminum Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Experimental Results ◽  
Steel Matrix ◽  
Milling Cutter ◽  
Side Milling ◽  
Radial Depth

This paper presents the experimental results of cutting performance and tool wear of a milling cutter in dry side milling of aluminum alloy A2017. The milling cutter consists of Co-bonded High-Speed-Steel matrix with Diamond-Like-Carbon coating (abbrev. DLC-coated HSS-Co cutter). The machining experiments were carried out under cutting speed of 63 to 189 [m•min-1] and feed of 0.08 [mm/tooth/rev], and the criterion of tool life was the generation of gauge and/or scratch on a machined surface. The experimental results support that the DLC-coated cutter in up cutting has good performance among four types of combination by the presence or absence of coating and the up/down cutting manner. They also showed that the tool life of DLC-coated cutter in up cutting under cutting speed of 157 [m•min-1] was corresponding to the cutting distance of 80 [m] with average width of flank wear 102 [μm] and that in down cutting was 60 [m] with 85 [μm]. In the range of cutting distance up to 100 [m], the resultant cutting force with the DLC-coated cutter was smaller than that with a non-coating cutter. In case of the DLC-coated cutter in up cutting under the cutting speed of 189 [m•min-1], a chatter vibration occurred during the initial cutting distance. In case of the radial depth of cut of 1.5 [mm], it lasted up to the cutting distance of 10 [m] and more.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Technological Investigation of Effect of Machining Parameter on Tool Life

2020 ◽  
Vol 22 (4) ◽  
pp. 41-53
Author(s):  
Manojkumar Sheladiya ◽  
◽  
Shailee Acharya ◽  
Ghanshyam Acharya ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Time ◽  
Machining Parameter

Introduction. The machinability is typical criteria to be investigated and different authors suggested different parameters describing its quantification. Different parameters i. e. speed, feed, depth of cut, tool work-piece combination, machine types and its condition, cutting fluid, machinist expertise, etc. are contributing directly to the tool life. The selection of the tool for the machining impacts greatly on the economic viability of the machining in terms of energy usage and tooling costs. The method of investigation. The current research emphasis mainly on tool life investigation when machining the mild steel specimens ISRO 50, BIS 1732:1989 at constant cutting speed i.e. 200 m / min. In the industries the mild steel material is commonly used for various products manufacturing. Considering the high demands on productivity and surface finish, machining at 200 m / min is the preferred. The computerized numerical control machine (CNC DX-150) is used for the turning. The four corner insert (TNMG 120408) is used for different machining times i.e. 10, 15, 20 and 25 minutes respectively. The flank wear of the tool is measured with calibrated optical microscope. The temperature of the tool corner during machining is continuously measured for possible impact of temperature on bonding properties of the tool insert and impact on red hardness. Results and discussion. The plot of flank wear vs. machining time will give the value of tool life. The other quality output parameter, such as surface roughness, is measured after machining, indicating surface irregularities in root means square value. Efforts have been made to identify the relationship of tool life, machining time, the quantity of metal removed, surface roughness, and tool bit temperature.

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