Tool wear in high speed machining

2000 ◽  
Vol 10 (PR9) ◽  
pp. Pr9-541-Pr9-546 ◽  
Author(s):  
A. Molinari ◽  
M. Nouari
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Machining

A Fracture Mechanics Approach to the Prediction of Tool Wear in Dry High Speed Machining of Aluminum Cast Alloys: Part 2 — Model Calibration and Verification

Tribology ◽  
2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Fracture Mechanics ◽  
Tool Wear ◽  
Model Calibration ◽  
High Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Wear Model ◽  
Wide Range ◽  
Cast Alloys

Experimental study has been carried out to establish the effect of cutting conditions (speed, feed, and depth of cut) on the cutting forces and time variation of carbide tool wear data in high-speed machining (face milling) of Al-Si cast alloys that are commonly used in the automotive industry. The experimental setup and force measurement system are described. The test results are used to calibrate and validate the fracture mechanics-based tool wear model developed in Part 1 of this work. The model calibration is conducted for two combinations of cutting speed and a feed rate, which represent a lower and upper limit of the range of cutting conditions. The calibrated model is then validated for a wide range of cutting conditions. This validation is performed by comparing the experimental tool wear data with the tool wear predicted by calibrated cutting tool wear model. The prediction errors were found to be less then 7%, demonstrating the accuracy of the object oriented finite element (OOFE) modeling of the crack propagation process in the cobalt binder. It also demonstrates its capability in capturing the physics of the wear process. This is attributed to the fact that the OOF model incorporates the real microstructure of the tool material.

Highlights of the DARPA Advanced Machining Research Program

1985 ◽  
Vol 107 (4) ◽  
pp. 325-335 ◽  
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.

High Speed Machining: A Review from a Viewpoint of Chip Formation

2011 ◽  
Vol 188 ◽  
pp. 578-583 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Masahiro Anzai ◽  
Tsuneo Egawa ◽  
Norihiko Narutaki ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Life Span ◽  
High Speed ◽  
Cutting Speed ◽  
Strong Nonlinearity ◽  
High Speed Machining ◽  
Cast Irons ◽  
Sliding Test ◽  
Cutting Experiments ◽  
Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

Evaluation of Tool Wear Suppressive Ability of Lubricants Usein in Minimum Quantity Lubrication Application in High Speed Machining of Cast Aluminum Alloys

2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Minimum Quantity Lubrication ◽  
Metalworking Fluids ◽  
High Speed Machining ◽  
Cast Aluminum ◽  
Tool Wear Rate ◽  
Cast Aluminum Alloys ◽  
Lubricant Composition

The disadvantages of conventional metalworking fluids such as disposal problems, health problems and economic factors have led to the development of strategies to reduce their amount in metalworking. Recently, Minimum Quantity Lubrication (MQL) technology was developed and it seems to be a suitable alternative for economically and environmentally compatible production. It combines the functionality of lubrication with an extremely low consumption of lubricant and has a potential to replace metalworking fluids application in machining operations. The MQL lubricants are formulated with two major groups of additives; anti-wear (AW) additives and extreme pressure (EP) additives. When such lubricants are applied to the cutting zone, protective layers are formed on the interacting surfaces of the workpiece and the cutting tool. These layers prevent direct contact between the tool and chip surfaces, and, therefore reduce friction forces and tool wear. In order to utilize MQL to its full potential, it is essential to select appropriate lubricant composition for particular work material and machining parameters. The experimental study of different compositions of MQL lubricants is reported. The effectiveness of the lubricants are determined in terms of their ability to protect the cutting tool in high speed machining of cast aluminum alloys, which are widely used in automotive industry. The main objective of this research is to quantitatively evaluate the ability of lubricant’s additive composition to reduce the tool wear. This is reached through the comparison between the tool wear rate measured during the machining of aluminum cast alloy with the application of MQL, and the tool wear rate obtained in dry machining of the same alloy. Two kinds of the lubricants are evaluated; vegetable and synthetic. The content of AW and EP additives in each kind of lubricant was varied on three levels in order to capture the effect of the lubricant’s composition on tool wear. The result of the MQL lubricants evaluation is discussed and the recommendations for optimal lubricant composition are made.

scholarly journals STUDY WEAR TOOL WITH HIGH-SPEED MILLING

2017 ◽  
Vol 3 ◽  
pp. 117
Author(s):  
Tsvetan Kaldashev ◽  
Petar Hadzhiyski ◽  
Galina Nikolcheva
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
High Speed ◽  
Milling Machine ◽  
High Speed Machining ◽  
Geometric Correction ◽  
High Speed Milling ◽  
Wear Tool

This report examined tool wear in high-speed machining of tool steel with a hardness of HRC 63. Wear monitored periodically using the device for automatic geometric correction tool (length and radius) situated in the working area of the machine. The study was conducted on milling machine RAIS M400 with CNC Heidenhain iTNC 530i.

scholarly journals Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V

Materials ◽  
2019 ◽  
Vol 12 (22) ◽  
pp. 3749 ◽  
Author(s):  
Adel T. Abbas ◽  
Neeraj Sharma ◽  
Saqib Anwar ◽  
Faraz H. Hashmi ◽  
Muhammad Jamil ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Optimization Approach ◽  
High Speed Machining

Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.

A Strategy of Toolpath Generation for Finish Machining of Mold Cavity Based on Tool-Zmap Model

2009 ◽  
Vol 407-408 ◽  
pp. 273-278
Author(s):  
Yu Jun Cai ◽  
Chun Zheng Duan ◽  
Li Jie Sun
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Geometric Model ◽  
Cutting Tools ◽  
Mold Cavity ◽  
High Speed Machining ◽  
Cutting Tool Wear ◽  
Finish Machining ◽  
Toolpath Generation

A strategy of toolpath generation based on Tool-Zmap geometric model has been proposed to achieve efficient finish machining of mold cavity. Considering cutting tool wear, the finish machining of mold cavity was performed using variable cutting tools of different diameter. Each cutting tool only cuts the corresponding area to avoid identifying machining characteristic and poor rigidity of cutting tool during high speed machining. Finally, the validity of presented strategy was experimentally affirmed by a machining example.

Investigation of tool wear in High Speed Machining by using a ballistic set-up

Wear ◽  
2009 ◽  
Vol 267 (9-10) ◽  
pp. 1673-1679 ◽  
Author(s):  
G. List ◽  
G. Sutter ◽  
X.F. Bi
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Machining ◽  
Set Up

Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

2011 ◽  
Vol 189-193 ◽  
pp. 3142-3147 ◽  
Author(s):  
Dong Qiang Gao ◽  
Zhong Yan Li ◽  
Zhi Yun Mao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

Sign in / Sign up

Export Citation Format

Share Document