Tribological Aspects of Metal Cutting

1993 ◽  
Vol 115 (3) ◽  
pp. 372-376 ◽  
Author(s):  
B. M. Kramer
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Chemical Properties ◽  
Work Piece ◽  
Metallic Surfaces ◽  
Tool Materials ◽  
Real Area Of Contact ◽  
Tribological System ◽  
High Pressure High Temperature ◽  
Physical And Chemical

The machining of metals presents a unique tribological situation in which atomically clean, metallic surfaces are cleaved from the interior of the workpiece and maintained in a condition of nearly 100 percent real area of contact with the tool surface during sliding. The conditions of high pressure, high temperature, and essentially uncontaminated contact during sliding create a highly ideal tribological system for analysis. As compared to conventional sliding wear, the analysis of which is complicated by multiple passes of the counterface materials and various forms of contamination and surface reaction, the predictive modeling of tool wear has achieved somewhat greater, if still modest, success. Current models of cutting tool wear are assessed with regard to their usefulness in developing quantitative analytical methods for designing new tool materials and for selecting optimum tool materials under variations in cutting conditions. Approaches which predict the relative wear resistances of potential tool materials from the physical and chemical properties of the tool-work-piece system, without recourse to calibration tests for each system, are emphasized.

Methods of Forecasting Wear Resistance of Cutting Tools Based on the Properties of their Materials

2014 ◽  
Vol 682 ◽  
pp. 491-494 ◽  
Author(s):  
Vladislav Bibik ◽  
Elena Petrova
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Chemical Properties ◽  
Tool Material ◽  
Composition Structure ◽  
Metal Cutting Tool ◽  
Physical And Chemical ◽  
Thermo Physical Properties

The author considers methods of forecasting metal-cutting tool life based on characteristics of cutting tool material. These characteristics depend on differences in numerical values of physical and chemical properties of tool material due to changes in its composition, structure, and production process variables. The described methods allow obtaining the information necessary for forecasting the tool life beyond the process of cutting, for example at the stage of cutting tool manufacturing. The author suggests using the method of registration of thermo-physical properties of the tool material as a promising forecasting technique.

scholarly journals Design and Development of a Three Component Milling Dynamometer

2021 ◽  
Vol 2070 (1) ◽  
pp. 012168
Author(s):  
Narender Maddela ◽  
Ch.Sai Kiran ◽  
Aluri Manoj ◽  
M. Kapila ◽  
B. Swapna ◽  
...  
Keyword(s):  
Tool Wear ◽  
Heat Generation ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Strain Gauges ◽  
Tool Geometry ◽  
Work Piece ◽  
Design And Development ◽  
Machined Surface

Abstract The cutting forces that are generated during metal cutting influence the work piece precision, tool wear, the nature of the machined surface, and heat generation. These cutting forces can be measured analytically however; precise outcomes may not be expected due to its included stresses, parameters of cutting, and the perplexing tool geometry. Henceforth the exploratory estimation of cutting forces is fundamental. For this reason, a milling dynamometer of three-segment is structured, created, and tried to gauge the three cutting forces which are produced during the operation of milling strain gauges can be utilized to quantify dynamic and static cutting forces through milling dynamometer. During the process of metal cutting, a dynamometer that is based on strain gauge is fit for estimating three-force segments. The dynamometer was designed based on the octagonal ring principle. The octagonal rings orientation and location of strain gauges have resolved to expand affectability and to limit cross-affectability.

scholarly journals Influence of machining conditions on friction in metal cutting process – A review

Mechanik ◽  
2019 ◽  
Vol 92 (4) ◽  
pp. 242-248
Author(s):  
Wit Grzesik ◽  
Joel Rech
Keyword(s):  
Tool Wear ◽  
Contact Zone ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Sliding Velocity ◽  
Contact Conditions ◽  
Tool Materials ◽  
Cutting Zone ◽  
Cooling Media ◽  
Cutting Tool Materials

This paper presents a range of variable machining factors which influence substantially friction directly or by the tool wear developed in the cutting zone. The group of direct factors include the workpiece and cutting tool materials coupled, the cutting/sliding velocity, cooling media supplied to the tool-chip contact zone, modification of the tool contact faces by micro-texturing. Special attention was paid to the tool wear evolution and its pronounced effect on changes of the contact conditions.

scholarly journals Boron–oxygen complex yields n-type surface layer in semiconducting diamond

2019 ◽  
Vol 116 (16) ◽  
pp. 7703-7711 ◽  
Author(s):  
Xiaobing Liu ◽  
Xin Chen ◽  
David J. Singh ◽  
Richard A. Stern ◽  
Jinsong Wu ◽  
...  
Keyword(s):  
Chemical Properties ◽  
Shallow Donor ◽  
Boron Doped Diamond ◽  
Boron Doped ◽  
High Pressure High Temperature ◽  
Type Semiconductor ◽  
High Carrier ◽  
Semiconducting Diamond ◽  
P Type ◽  
Physical And Chemical

Diamond is a wide-bandgap semiconductor possessing exceptional physical and chemical properties with the potential to miniaturize high-power electronics. Whereas boron-doped diamond (BDD) is a well-known p-type semiconductor, fabrication of practical diamond-based electronic devices awaits development of an effective n-type dopant with satisfactory electrical properties. Here we report the synthesis of n-type diamond, containing boron (B) and oxygen (O) complex defects. We obtain high carrier concentration (∼0.778 × 1021 cm−3) several orders of magnitude greater than previously obtained with sulfur or phosphorous, accompanied by high electrical conductivity. In high-pressure high-temperature (HPHT) boron-doped diamond single crystal we formed a boron-rich layer ∼1–1.5 μm thick in the {111} surface containing up to 1.4 atomic % B. We show that under certain HPHT conditions the boron dopants combine with oxygen defects to form B–O complexes that can be tuned by controlling the experimental parameters for diamond crystallization, thus giving rise to n-type conduction. First-principles calculations indicate that B3O and B4O complexes with low formation energies exhibit shallow donor levels, elucidating the mechanism of the n-type semiconducting behavior.

Influence of the Electric Field Voltage on the Microhardness of the Layers Coated by Thermal Spraying

2014 ◽  
Vol 216 ◽  
pp. 316-321 ◽  
Author(s):  
Ionut Claudiu Roată ◽  
Alexandru Pascu ◽  
Elena Manuela Stanciu
Keyword(s):  
Electric Field ◽  
Thermal Spraying ◽  
Chemical Properties ◽  
Work Piece ◽  
Electric Device ◽  
Metallic Body ◽  
Displacement Speed ◽  
Physical And Chemical ◽  
The Impact ◽  
Electric Loads

This study focuses on the analysis of the electric field voltage influence on the microhardness of the layers coated by thermal spraying. Based on the fact that the loads that are oppositely signed are attracted, an electric device of electric field generating in alternating current is developed, the electric field being generated between the metalizing gun and the work piece. Any metallic body that crosses the electric field is loaded with electric loads, which are yielded by an electric discharge when meeting the oppositely signed load. Thus, the physical and chemical properties of the layers coated by thermal spraying are improved by enhancing the powders displacement speed and by the appearance of micro weldings at the impact between the powder and the metalizing piece. After the samples analysis, an improvement of the diffusion zone is noticed and also an increasing of the microhardness for the samples at which the following voltages are used U = 30; 50; 70 [. In order to achieve the experimental samples, the CastoDyn DS8000 thermal spraying unit, the standard metallization module SSM 10 and the nickel based powder ProXon 21021 were used.

Integrated System for Monitoring the Tool State Using Temperature Measuring by Natural Thermocouple Method

2014 ◽  
Vol 1036 ◽  
pp. 274-279 ◽  
Author(s):  
Marinela Inţă ◽  
Achim Muntean
Keyword(s):  
Acoustic Emission ◽  
Tool Wear ◽  
Manufacturing Systems ◽  
Metal Cutting ◽  
Block Diagram ◽  
Cutting Temperature ◽  
Integrated System ◽  
Work Piece ◽  
Tool Temperature ◽  
On Line

The intensive developments of intelligent manufacturing systems in the last decades open the large possibilities of more accurate monitoring of the metal cutting process. One of the most important factors of the process is the tool state given by the rate of the tool wear, which is the result of a lot of influences of almost all cutting parameters. The modern tool monitoring systems relieved that the accuracy of the results increases when using a combination of surveyed signals such as: vibrations, power consumption, acoustic emission, forces or tool temperature. Combining the output signals in a monitoring function using the neural network method gives the best results when using on-line monitoring. Considering the tool temperature as an important factor in the tool wear process and adding it to the acoustic emission and force measuring the accuracy of the results seems to improve significantly. The present paper describes an integrated monitoring system with integration of the cutting temperature, the calibration device for work piece-tool thermocouple, and the block diagram for on-line survey measuring using LabView platform.

scholarly journals Experimental Investigation on Effects of MQL on Surface Finish and Tool Wear in Turning of SAE 1018

2018 ◽  
Vol 7 (2) ◽  
pp. 67-69
Author(s):  
Sandeep Kumar ◽  
Sukhpal Singh Chatha ◽  
Rutash Mittal
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Metal Cutting ◽  
Substantial Reduction ◽  
Minimum Quantity Lubrication ◽  
Environmental Safety ◽  
Work Piece ◽  
Cutting Fluids ◽  
Nose Radius ◽  
Machining Processes

In all machining processes, tool wear is a major problem and it leads to tool failure. In metal industries, the use of cutting fluids affects both employee’s health and environmental pollution. But the use of cutting fluids becomes necessary to keep tight tolerances and to maintain the work-piece surface properties without damages. Researchers are trying to reduce the use of coolant lubricant fluids in metal cutting to obtain environmental safety. So, to minimize the use of cutting fluids new cutting techniques are investigated. Minimal quantity of Lubrication (MQL) is a recent technique introduced in machining to obtain less tool wear and environment safety. The minimum quantity lubrication was provided with a spray of mixture of air and vegetable oil at suitable pressure. MQL machining was performed much superior compared to dry and wet machining due to substantial reduction in tool wear and cutting zone temperature and a better surface finish. MQL provides neat and clean environment avoiding health hazards due to smoke, fumes and gases etc. In this study work-piece of SAE 1018 were prepared to investigate their Surface finish under turning with coated tool bits. Wear of nose radius of tool bits were analyzed by SEM which results in less wear in MQL process as compared to flood cooling.

Tool Materials for Turning Machine-Building Stainless Steel 09Kh17N7Yu

2021 ◽  
pp. 27-33
Author(s):  
B.Y. Mokritskiy ◽  
E.S. Sitamov
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
High Performance ◽  
Metal Cutting ◽  
Operating Time ◽  
Tool Material ◽  
Machine Building ◽  
Operating Conditions ◽  
Software Environment ◽  
Tool Materials

Hard-to-process specialized stainless steel grade 09Kh17N7Yu has become widely used in various fields of mechanical engineering due to its unique performance properties. The existing recommendations for its processing are outdated and do not meet modern requirements for the performance of metal-cutting tools. This necessitated the need to develop recommendations for modern high-performance machine tools. The paper presents methods of solving this problem based on the example of turning by typical domestic replaceable hard-alloyed cutting plates. Relationships between the tool wear and the operating time were obtained. Design solutions for tool materials to be used under specified operating conditions were developed. A significant outcome of the paper was the use of simulation modeling in the Deform software environment, which allowed the authors to develop new coatings for the hard alloy VK8, which provided a significant (up to 3 times) increase in tool life. Using modelling, it was also possible to design new tool materials for new or expected operating conditions. The following main criteria sufficient for modeling were identified: tool wear, temperature in the cutting zone, stresses in the tool material and deformation of the tool material. The results obtained can be used as the basis for the so-called data bank, which can be used in production enterprises.

Evaluation of Single Layer Hafnium Nitride Coated Tool for Metal Cutting

2016 ◽  
Vol 1815 ◽  
Author(s):  
John Henry Navarro Devia ◽  
Willian Aperador Chaparro ◽  
Jairo Cortes Lizarazo
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Single Layer ◽  
Numerical Control ◽  
Process Time ◽  
Work Piece ◽  
Hafnium Nitride

ABSTRACTThe main purpose of coatings is to increase the lifetime of cutting tools, to perform continuous and economical material removal process, reducing the frequency of sharpening or replacement of the tool, which contributes to increase quality of product. Therefore, hafnium nitride (HfN) single layer coatings were deposited on High-speed steel by Magnetron Sputtering physical vapour deposition (PVD). The machining on AISI 1020 steel samples were carried out in a computer numerical control (CNC) machine, using coated and uncoated tools, the temperature of the different components were measured (steel bar and tool), due to continuous temperature measurement help to predict tool wear and the quality of finished piece [1] . In order to evaluate wear resistance and performance, not only temperature data were compared, the tool wear morphological analysis for flank wear was carried using Scanning Electron Microscopy (SEM), and work pieces roughness were checked through their surfaces in an Atomic Force Microscopy (AFM). In most of the parameters evaluated differences between the tools were identified, and results reveals that on HfN coating, occurs less wear, due the proportionality between the energy transfer and the tool deterioration, also the coating improves surface finish of the machined part; all of them are reflected in changes on process temperatures. The use of single layer HfN coating on cutting tools could increase their lifetime, improve the quality of the work piece, and even reduce process time and cost.

scholarly journals Tribological Performance of Micro-Groove Tools of Improving Tool Wear Resistance in Turning AISI 304 Process

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1236 ◽  
Author(s):  
Jinxing Wu ◽  
Gang Zhan ◽  
Lin He ◽  
Zhongfei Zou ◽  
Tao Zhou ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Chemical Properties ◽  
Contact Length ◽  
Aisi 304 ◽  
New Type ◽  
Flank Face ◽  
Physical And Chemical ◽  
Oxidation Wear ◽  
Hard Cutting

AISI 304 has good physical and chemical properties and thus is widely used. However, due to the low thermal diffusivity, the cutting temperature of AISI 304 is high accelerating the wear of the tool. Therefore, tool wear is a major problem in machining hard cutting materials. In this study, we developed a new type of micro-groove tool whose rake surface was distributed with micro-groove by powder metallurgy based on the finite element temperature field morphology. We compared the wear of the proposed micro-groove tool with an untreated one by using a scanning electron microscope (SEM) and an X-ray energy spectrum. The abrasive, adhesive, and oxidation wear of the rake and the flank face of the micro-groove tool were lower than that of the untreated one. Due to the micro-groove on the rake face of the tool, the contact length between the tool and chip was reduced, leaving more extension space. Furthermore, chip extrusion deformation was avoided, and the energy caused by chip deformation was reduced. After 70 min of cutting, the counterpart reached the specified wear amount while the main cutting force, the feed resistance, and the cutting depth resistance of the proposed micro-groove tool were reduced by 16.1%, 33.9%, and 40.1%, respectively. With regard to steady state, the cutting temperature was reduced by 17.2% and the wear width of the flank face was reduced by 36.7%.

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