Experimental observation of tool wear, cutting forces and chip morphology in face milling of cobalt based super-alloy with physical vapour deposition coated and uncoated tool

2007 ◽  
Vol 28 (6) ◽  
pp. 1880-1888 ◽  
Author(s):  
Şeref Aykut ◽  
Eyup Bagci ◽  
Aykut Kentli ◽  
Osman Yazıcıoğlu
Keyword(s):  
Tool Wear ◽  
Experimental Observation ◽  
Cutting Forces ◽  
Vapour Deposition ◽  
Chip Morphology ◽  
Face Milling ◽  
Physical Vapour Deposition ◽  
Super Alloy

scholarly journals Fractal Characteristics of Chip Morphology and Tool Wear in High-Speed Turning of Iron-Based Super Alloy

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 1020
Author(s):  
Xu Zhang ◽  
Guangming Zheng ◽  
Xiang Cheng ◽  
Rufeng Xu ◽  
Guoyong Zhao ◽  
...  
Keyword(s):  
Fractal Dimension ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
Fractal Dimensions ◽  
Chip Morphology ◽  
Color Changes ◽  
Fractal Characteristics ◽  
Iron Based ◽  
Super Alloy

Considering that iron-based super alloy is a kind of difficult-to-cut material, it is easy to produce work hardening and serious tool wear during machining. Therefore, this work aims to explore the chip change characteristics and tool wear mechanism during the processing of iron-based super alloy, calculate the fractal dimensions of chip morphology and tool wear morphology, and use fractals to analyze their change trend. Meanwhile, a new cutting tool with a super ZX coating is used for a high-speed dry turning experiment. The results indicate that the morphology of the chip is saw-tooth, and its color changes gradually, due to the oxidation reaction. The main wear mechanisms of the tool involve abrasive wear, adhesive wear, oxidation wear, coating spalling, microcracking and chipping. The fractal dimension of the tool wear surface and chip is increased with the improvement of cutting speed. This work investigates the fractal characteristics of chip morphology and tool wear morphology. The fractal dimension changes regularly with the change of tool wear, which plays an important role in predicting this tool wear. It is also provides some guidance for the efficient processing of an iron-based super alloy.

Acoustic Emission Sensing of Tool Wear in Face Milling

1987 ◽  
Vol 109 (3) ◽  
pp. 234-240 ◽  
Author(s):  
E. N. Diei ◽  
D. A. Dornfeld
Keyword(s):  
Acoustic Emission ◽  
Tool Wear ◽  
Cutting Forces ◽  
Flank Wear ◽  
Face Milling ◽  
Processing Scheme ◽  
Acoustic Emission Sensing ◽  
Vertical Milling Machine ◽  
Time Domain Averaging ◽  
Ae Signals

Acoustic Emission (AE) signal analysis was applied to on-line sensing of tool wear in face milling. Cutting tests were conducted on a vertical milling machine. AE signals, feed and normal components of cutting force and flank wear were measured and compared. A signal processing scheme for intermittent cutting forces and AE signals, based on the concept of time domain averaging (TDA) is proposed. The results indicate that both AE and cutting forces have parameters that correlate closely with flank wear.

Wear and cutting forces in high-speed machining of H13 using physical vapour deposition coated carbide tools

2005 ◽  
Vol 219 (2) ◽  
pp. 191-199 ◽  
Author(s):  
P T Mativenga ◽  
K K B Hon
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Vapour Deposition ◽  
High Speed Machining ◽  
Physical Vapour Deposition ◽  
Tin Coatings ◽  
Tool Coatings ◽  
Process Trends ◽  
Coated Carbide ◽  
Coated Carbide Tools

This paper reviews the contributions that coatings make in enhancing the cutting performance of carbide tools and, in particular, their application in high-speed machining. It examines flank wear and cutting force process trends that are essential for monitoring tool degradation in automated machining factories. The findings of the investigation into cutting forces over the life cycle of different physical vapour deposition (PVD) tool coatings on micrograin carbide in the high-speed machining of tool steel are presented and related to the existing literature. Cutting tests were carried out at a very high spindle speed, 40000 r/min, and for a predetermined cutting time. Variants of the TiAlN coating, i.e. single- and double-layer and composite coating enhanced with WC/C, were evaluated against the uncoated tool and the TiCN, CrN, and TiN coatings. The paper reflects on the performance of advanced PVD coatings and also presents force trends and suggestions for process monitoring.

The Influence of Cryogenic Coolants in Machining of Ti–6Al–4V

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
B. Dilip Jerold ◽  
M. Pradeep Kumar
Keyword(s):  
Carbon Dioxide ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Fluids ◽  
Cryogenic Machining ◽  
The Past ◽  
Carbon Dioxide Co2 ◽  
Made In

Machining of titanium alloy Ti–6Al–4V is a challenging task because of the greatly increased cutting temperature that results in short tool life. Numerous attempts have been made in the past by employing various cutting fluids for machining purpose, including liquid nitrogen (LN2) as the cryogenic coolant. This study deals with the influence of cryogenic coolants, especially LN2 and carbon dioxide (CO2), in machining of Ti–6Al–4V and its effects on cutting temperature, cutting forces, surface roughness, chip morphology, and tool wear. The results obtained in cryogenic machining are compared with that of dry and wet machining. Cutting temperature was reduced to an extent of 36% and 47% in cryogenic CO2 machining and cryogenic LN2 machining in comparison with wet machining. The application of CO2 produced reduced cutting forces up to 24% and improved surface finish up to 48% compared to cryogenic LN2 machining. It also produced better chip control and minimized tool wear than dry, wet, and LN2 machining.

scholarly journals Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771370 ◽  
Author(s):  
Anhai Li ◽  
Jun Zhao ◽  
Guanming Hou
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Wear Mechanisms ◽  
Failure Mechanisms ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Face Milling ◽  
Formation Mechanisms ◽  
Tool Wear Mechanisms ◽  
Cutting Speeds

Chip morphology and its formation mechanisms, cutting force, cutting power, specific cutting energy, tool wear, and tool wear mechanisms at different cutting speeds of 100–3000 m/min during dry face milling of Ti-6Al-4V alloy using physical vapor deposition-(Ti,Al)N-TiN-coated cemented carbide tools were investigated. The cutting speed was linked to the chip formation process and tool failure mechanisms of the coated cemented cutting tools. Results revealed that the machined chips exhibited clear saw-tooth profile and were almost segmented at high cutting speeds, and apparent degree of saw-tooth chip morphology occurred as cutting speed increased. Abrasion in the flank face, the adhered chips on the wear surface, and even melt chips were the most typical wear forms. Complex and synergistic interactions among abrasive wear, coating delamination, adhesive wear, oxidation wear, and thermal mechanical–mechanical impacts were the main wear or failure mechanisms. As the cutting speed was very high (>2000 m/min), discontinuous or fragment chips and even melt chips were produced, but few chips can be collected because the chips easily burned under the extremely high cutting temperature. Large area flaking, extreme abrasion, and serious adhesion dominated the wear patterns, and the tool wear mechanisms were the interaction of thermal wear and mechanical wear or failure under the ultra-high frequency and strong impact thermo-mechanical loads.

scholarly journals Experimental investigation of specific cutting forces and estimation of the heat partitioning under increasing tool wear in machining nickel-based super alloy IN 718

2020 ◽  
Vol 14 (4) ◽  
pp. 491-498
Author(s):  
Thorsten Augspurger ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Heat Flow ◽  
Tool Wear ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Milling Process ◽  
Measuring System ◽  
Heat Partitioning ◽  
Wear Monitoring ◽  
Continuous Heat ◽  
Super Alloy

Abstract Presented are an experimental setup and affiliated methodology to measure the specific cutting forces in the milling process with proceeding tool wear at simplified orthogonal milling kinematics. The cutting forces, cutter rotation angle and chip temperature are acquired by a time sensitive measuring system consisting of a synchronized dynamometer, ratio pyrometer and spindle encoder. The approach allows the accurate acquisition of cutting forces under defined engagement conditions and thus constitutes a valuable basis for cutting force modelling and tool wear monitoring approaches. The results show uniformly and linearly increasing forces over the entire range of undeformed chip thickness due to wear. Besides a mechanical view on the cutting process, also the thermal domain was included into the analysis. Therefore, a ratio pyrometer was used as part of the synchronized measurement system tracking the chips backside temperature in order to estimate a virtually continuous heat flow into the chip. This heat flow increased with wear and process power, which indicates that the chip’s temperature can be used as process monitoring variable for tool wear.

FE Simulation of Cryogenic Assisted Machining of Ti Alloy (Ti6AI4V)

2015 ◽  
Author(s):  
Vivek Bajpai ◽  
Ineon Lee ◽  
Hyung Wook Park
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Cutting Forces ◽  
Turbine Blades ◽  
Chip Morphology ◽  
Machining Process ◽  
Burr Formation ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Ti Alloys

Titanium alloys are well-known material because of the excellent mechanical/chemical properties, corrosion resistance and light weight. These alloys are widely used in the high performance applications such as; aerospace, aviation, bio-implants, turbine blades etc. Machining is commonly used to create products out of Ti alloys. Despite of good material properties, Ti alloys have low thermal conductivity, poor machinability, burr formation, high machining temperature, tool wear and poor machinability. The tool wear and high machining temperature can be controlled through coolant. Cryogenic fluid (liquid nitrogen) is a common material used as coolant in various machining process. The current work is focused on the modeling of cryogenic machining on titanium alloy (Ti6Al4V). Dry machining and cryogenic machining processes are modeled for the chip formation and cutting forces in 2D. Experimental works have been performed to validate the model based on the cutting forces and chip morphology. It is showed that the model is capturing the process, evident by the cutting forces and the chip morphology. The error in prediction is limited to 18%. Model showed that the cutting forces are increasing in cryogenic machining due to the increased strength of the workpiece at low temperature. Chip formation is well captured by the current model. Shear band width have been captured in dry machining. Chip curling has been captured at dry and cryogenic machining. It is expected that the model can further useful in the selection of cryogenic process parameter, such as, flow rate, application techniques etc.

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