An Investigation of Forces and Tool Wear in Milling of Ni3Al-Base Superalloy

2016 ◽  
Vol 861 ◽  
pp. 32-37
Author(s):  
Gao Qun Liu ◽  
Zheng Cai Zhao ◽  
Yu Can Fu ◽  
Zhi Liang Yan
Keyword(s):  
Tool Wear ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Ticn Coating ◽  
Radial Depth ◽  
Tools Wear

This article studies the forces and tool wear behavior in the milling process of Ni3Al-base superalloys with cemented carbide cutting tools. The effects of cutting parameters on the machinability of these superalloys are experimentally discussed. The results indicate that the forces increase with the increase of the axial depth of cut, the radial depth of cut and the feedrate per tooth. The cutting tools wear rapidly in the milling process of Ni/Al superalloys. The cemented carbide cutting tool with TX coating is more suitable for machining Ni/Al superalloys when compared with the tool with TiCN coating.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

Comparison of CVD and MOCVD-grown Al2O3 coatings in the performance of cemented carbide cutting tool inserts

2011 ◽  
Vol 1298 ◽  
Author(s):  
Piyush Jaiswal ◽  
Abdul Sathar ◽  
Arshiyan Shariff ◽  
Mohammed Saif ◽  
Sukanya Dhar ◽  
...  
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Superior Performance ◽  
Depth Of Cut ◽  
Carbide Cutting Tool ◽  
Industry Standard ◽  
Low Pressure Mocvd ◽  
Steel Turning

ABSTRACTLow-pressure MOCVD, with tris(2,4-pentanedionato)aluminum(III) as the precursor, was used in the present investigation to coat alumina on to cemented carbide cutting tools. To evaluate the MOCVD process, the efficiency in cutting operations of MOCVD-coated tools was compared with that of tools coated using the industry-standard CVD process.Three multilayer cemented carbide cutting tool inserts, viz., TiN/TiC/WC, CVD-coated Al2O3 on TiN/TiC/WC, and MOCVD-coated Al2O3 on TiN/TiC/WC, were compared in the dry turning of mild steel. Turning tests were conducted for cutting speeds ranging from 14 to 47 m/min, for a depth of cut from 0.25 to 1 mm, at the constant feed rate of 0.2 mm/min. The axial, tangential, and radial forces were measured using a lathe tool dynamometer for different cutting parameters, and the machined work pieces were tested for surface roughness. The results indicate that, in most of the cases examined, the MOCVD-coated inserts produced a smoother surface finish, while requiring lower cutting forces, indicating that MOCVD produces the best-performing insert, followed by the CVD-coated one. The superior performance of MOCVD-alumina is attributed to the co-deposition of carbon with the oxide, due to the very nature of the precursor used, leading to enhanced mechanical properties for cutting applications in harsh environment.

Optimization of the Process Parameters in Milling of Aluminum Alloys

2020 ◽  
Vol 896 ◽  
pp. 293-298
Author(s):  
Nicolae Craciunoiu ◽  
Emil Nicusor Patru ◽  
Adrian Sorin Rosca ◽  
Dumitru Panduru ◽  
Marin Bica
Keyword(s):  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Experimental Conditions ◽  
Milling Parameters

In order to control the temperature during milling process of aluminum alloys and keeping as minimum as possible, the choice of the cutting parameters and their optimization is very important, both for the tool wear but also for the surface quality of machined surface. The main purpose of this paper is to find the optimum values of the milling parameters (rotational speed and depth of cut) so that the minimum value for the temperature to be obtained. Using adequate experimental conditions with contact measurements techniques (thermocouple K-type) carried out on the some types of aluminum alloys and the appropriate statistical instruments, the most influencing cutting parameters and their values on the cutting temperature can be found. The results are presented both analytical and graphical.

scholarly journals ENERGY-BASED CHARACTERIZATION OF PRECISION HARD MACHINING USING PARTIALLY WORN CBN CUTTING TOOLS

2019 ◽  
Vol 19 (2) ◽  
pp. 55-62 ◽  
Author(s):  
Wit GRZESIK ◽  
Berend DENKENA ◽  
Krzysztof ZAK
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Point Of View ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Additional Tool ◽  
Variable Feed Rate ◽  
Wear Tests

This paper highlights the performance of precision hard turning with CBN cutting tools from energy point- of-view with additional tool wear effect. For this purpose several wear tests were performed during which the tool nose wear VBC and the corresponding changes of component forces Fc, Ff and Fp were continuously measured. Based on the measured forces and geometrical characteristic of the uncut layer, specific cutting and ploughing energy were determined for several combinations of cutting parameters. Consequently, changes of energy consumption resulting from tool wear evolution for variable feed rate, depth of cut and tool nose radius were presented.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Autoresonant Tuning and Control in Ultrasonic Vibration Assisted Drilling Process

2006 ◽  
Vol 505-507 ◽  
pp. 823-828 ◽  
Author(s):  
Yu Chieh Chen ◽  
Yunn Shiuan Liao ◽  
J.D. Fan
Keyword(s):  
Cutting Parameters ◽  
Milling Process ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Drilling Process ◽  
Side Milling ◽  
Relational Analysis ◽  
Radial Depth ◽  
Grey Relational ◽  
Optimal Cutting Parameters

This paper presents an optimal cutting-parameter design of heavy cutting in side milling for SUS304 stainless steel. The orthogonal array with relational analysis is applied to optimize the side milling process with multiple performance characteristics. A grey relational grade obtained from the grey relational analysis is used as a performance index to determine the optimal cutting parameters. The selected cutting parameters are cutting speed, feed per tooth, axial depth of cut, and radial depth of cut, while the considered performance characteristics are tool life and metal removal rate. Experimental results have shown that cutting performance in the side milling process for heavy cutting can be significantly improved through this approach.

An Investigation on Machining Behaviour of Metal Matrix Composites by Using PCD Inserts

2005 ◽  
Author(s):  
N. Muthu Krishnan ◽  
D. Vikram ◽  
S. Kaushik ◽  
K. Prahalada Rao
Keyword(s):  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Wear Behavior ◽  
Removal Rate ◽  
Cutting Tools ◽  
Depth Of Cut ◽  
Matrix Composites ◽  
Worn Surface ◽  
Poly Crystalline Diamond

The present work has been undertaken to study the tool wear behavior of poly crystalline diamond (PCD) inserts during the machining of Al-SiC – MMC; Al-Si alloy containing 15%wt of SiC was used for machining and PCD inserts of three different grades were used as cutting tools. The main aim of this paper is to explore the feasibility of machining conditions by setting the spindle speed, depth of cut and thereby determining the cutting force, surface roughness, power consumed, material removal rate and tool wear. The worn surface of the insert was examined by Scanning electron microscope (SEM). The influence of cut was examined for the PCD inserts.

Flank Wear Mechanism of WC-5TiC-10Co Cemented Carbides Inserts when Machining HT250 Gray Cast Iron

2014 ◽  
Vol 670-671 ◽  
pp. 517-521 ◽  
Author(s):  
Jian Chen ◽  
Man Feng Gong ◽  
Shang Hua Wu
Keyword(s):  
Cast Iron ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Gray Cast Iron ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Gray Cast ◽  
Cemented Carbides ◽  
Depth Of Cut ◽  
Tool Wear Mechanism

WC–5TiC–10Co cemented carbides inserts were prepared and used for the cutting tool for HT250 gray cast iron. The objective was to investigate the wear mechanism when machining HT250 gray cast iron with WC–5TiC–10Co cemented carbides inserts. WC–10Co cemented carbides with the same sintering technology and grain size were prepared for comparison. wear mechanism was examined at the same cutting parameters. The cutting tests were performed at a speed of 120 m/min with feed rate of 0.2 mm/rev and a constant depth of cut of 0.2 mm under dry conditions. Tool wear mechanism is analyzed by SEM and EDS. Adhesive and built-up-edge were found to be the predominant tool wear for WC–5TiC–10Co cemented carbides inserts. However, Attrition was the main wear mechanisms observed in WC–10Co cutting tools. The results obtained indicated that WC–5TiC–10Co cutting tools performed better than WC–10Co cutting tools, in terms of tool wear with current parameters.

Physical Simulation of the Cutting Process Induced by Tool Geometric Angle and Cutting Parameters

2012 ◽  
Vol 430-432 ◽  
pp. 715-718 ◽  
Author(s):  
Xue Hui Wang ◽  
Ping Zhou ◽  
Ya Wen Liu ◽  
Ming Jun Dai
Keyword(s):  
Physical Simulation ◽  
Cutting Parameters ◽  
Simulation Method ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Process ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Solid Carbide

The tool geometric angle and cutting parameters have a significant influence on the titanium alloy milling process by the usage of solid carbide end mills.The physical simulation method was applied to predict the cutting force and temperature by using two comparative sets of simulation data such as the different tool gemetric angle as tool rake angle, helix angle and different cutting parameters such as spindle speed, axial depth of cut, radial depth of cut. Thus are the commonly used methods to simulate and predict the cutting process before the actual production, which can reduce product cost and time.

Cutting Parameters Impacting on Tool Wear in Micro End-milling of Tool Steel

2018 ◽  
Author(s):  
Cínthia Soares Manso ◽  
Cleiton Lazaro Fazolo de Assis ◽  
Luciana Wasnievski da Silva de Luca Ramos ◽  
Erik Gustavo Del Conte
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Diameter

In micro milling process, the quick wear and premature breakage of tools configure a problem that affects not only the process costs but also the manufacturing quality. This work investigates the influence of the cutting parameters on tool wear and surface roughness in a dry machining of a tool steel H13 workpiece (X40CrMoV5-1). Spindle speed was kept constant (27200 rpm) and two feeds per tooth were applied (1.5 and 3.0 µm) as depth of cut (25 and 30 µm), and variating cut length as well. The wear of the tool top area, tool diameter and nose radius were monitored during micro milling tests. Roughness was evaluated by using a Laser Confocal Microscope. The lower level of feed per tooth and depth of cut showed lower roughness, but a higher tool wear. A balance between cutting parameters and cutting length must be considered to ensure micromachining without severe tool wear and preserve microchannel features along its machined surface.

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