Microscopic Studies of Flank Wear on Alumina Tools

1991 ◽  
Vol 113 (1) ◽  
pp. 204-209 ◽  
Author(s):  
Sukyoung Kim ◽  
Delcie R. Durham
Keyword(s):  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Physical And Mechanical Properties ◽  
Thermal Conditions ◽  
Mechanical Wear ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Flank Surface ◽  
Aisi 4340

The flank wear of alumina cutting tools in the machining of annealed steels, AISI 1045 and 4340, which were approximately the same hardness, was studied microscopically. The intent was to establish whether any chemical wear occurred in addition to the mechanical wear on the flank surface. While the hardness of the two steels was essentially the same, the chemistry and the carbide present in the microstructure differed. The flank wear morphology was studied and three regions within the wear land could be defined. The flank wear of the alumina tools, which increased with an increase of cutting speeds, was found to be strongly dependent upon the chemistry of the work material being machined. At the higher speeds, the flank wear when cutting AISI 1045 steel was approximately twice that of AISI 4340. It was observed that different wear mechanisms could be associated with the material being machined. The thermally activated chemical and mechanical wear processes were predominant in the AISI 1045 machining, but the chemical wear was not significant in machining AISI 4340. At lower temperatures, the mechanical wear predominated for both steels. The wear pattern consisted of three regions on the flank wear surface, which varied with cutting speed, cutting distance, and position within the wear land. The surface roughness on the worn tool was also related to these same test parameters. The flank wear appears to depend upon not only the workpiece, but also upon an interfacial oxide layer that forms during cutting. The physical and mechanical properties of the interfacial oxide depend upon its constituents, which relate back to workpiece composition and thermal conditions at the interface.

scholarly journals Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3974 ◽  
Author(s):  
Mohamed Shnfir ◽  
Oluwole A. Olufayo ◽  
Walid Jomaa ◽  
Victor Songmene
Keyword(s):  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Mechanical Shock ◽  
Tool Edge ◽  
Aisi 1045 ◽  
High Feed ◽  
1045 Steel ◽  
Edge Preparation

Intermittent machining using ceramic tools such as hard milling is a challenging task due to the severe mechanical shock that the inserts undergo during machining and the brittleness of ceramic inserts. This study investigates the machinability of hardened steel AISI 1045 during face milling using SiAlON and whisker (SiCW) based ceramic inserts. The main focus seeks to identify the effects of cutting parameters, milling configuration, edge preparation and work material hardness on machinability indicators such as resultant cutting force, power consumption and flank tool wear. The effects of these varying cutting conditions on performance characteristics were investigated using a Taguchi orthogonal array design L32 (21 44) and evaluated using ANOVA. Results indicate lower resultant cutting forces were recorded with honed edge inserts of SiAlON ceramic grade. In addition, a decrease in resultant cutting forces was associated with reduced feed rates and increased hardness. The feed rate and cutting speed were also identified as the greatest influencing factors in the amount of cutting power. The main wear mechanisms responsible for flank wear on the ceramic inserts are micro-scale abrasion and micro-chipping. Increased flank wear was observed at low cutting speed and high feed rates, while micro-chipping mostly ensued from the cyclic loading of the radial tool edge form, which is more susceptible to impact fragmentation. Thus, the use of tools with chamfered tool-edge preparation greatly improved observed wear values. Additional confirmation tests were also conducted to validate the results of the tests.

scholarly journals Study on the Cutting Temperature of the Textured Tool by 3D FEA Simulation

2020 ◽  
Vol 1 (2) ◽  
Author(s):  
Siwen TANG ◽  
Pengfei LIU ◽  
Rui WANG ◽  
Qiulin NIU ◽  
Guoqing YANG ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Practical Method ◽  
Maximum Temperature ◽  
Feed Speed ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Temperature plays an important role in the life of cutting tools. However, it is sometimes difficult to observe instantaneously because of limited data acquisition, especially for the textured tool. In this paper, the performance of microgroove textured cutting tools for three-dimensional (3D) oblique dry turning of AISI 1045 steel was studied by finite element simulation. The effects of width, depth and spacing of strip micro-texture on cutting temperature and the effect of cutting speed on cutting temperature of strip micro-texture tool were studied. The results show that the maximum temperature of the tool and the tip temperature first increase and then decrease with the increase of micro-texture width. When the micro-texture depth increases, the maximum temperature and the tool tip temperature decrease first and then increase. The highest temperature and tip temperature of the tool gradually increase with the increase of micro-texture spacing. The highest temperature and tip temperature of the tool increase with the increase of cutting speed, feed speed and cutting depth. In addition, the effective mechanism of micro-texture parameter for the temperature was proposed. It provides profound guidance for optimizing the microstructure parameters and cutting process of cutting tools according to cutting temperature in this study. It also provides an effective and practical method for the design, innovation and development of micro-textured tools.

scholarly journals Fabrication and Machining Performance of Powder Compacted Alumina Based Cutting Tool

2018 ◽  
Vol 150 ◽  
pp. 04009 ◽  
Author(s):  
Hadzley Abu Bakar ◽  
Naim Fahmi ◽  
Faiz Mokhtar ◽  
Norfauzi Tamin ◽  
Umar Azlan ◽  
...  
Keyword(s):  
Wear Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Hydraulic Press ◽  
Machining Performance ◽  
Nose Radius ◽  
Wear Area ◽  
Aisi 1045 ◽  
1045 Steel

This study focuses on the fabrication of alumina based cutting tool for machining application. Specific weight of alumina powders were pressed in a mold using hydraulic press at 8 tons before compressed through Cold Isostatic Press (CIP) at 30000 psi. Green body then was dried and sintered at 1700 °C at 4 hours sintering time to form solid cutting tools. These cutting tools were then tested in turning operation to machine AISI 1045 with different cutting speeds. The results shows that CIP pressed alumina cutting tool obtained the hardness of 83.2 HRA which is considered adequate to machine AISI 1045 steel. The shrinkage of alumina powders recorded about 7% form green compact to sintered body. In terms of flank wear, the alumina cutting tool demonstrated decreased wear rate as the cutting speed increased from 150 m/min to 225 m/min. Wear area focused at the edge of cutting tool due to small nose radius with the minimum wear rate recorded at 0.0025 mm/s for 225 m/min cutting speed. The newly fabricated cutting tools can be improved if finer or secondary reinforced particles were used.

Development of Tooling Cost Model for High Speed Hard Turning

2011 ◽  
Vol 418-420 ◽  
pp. 1482-1485 ◽  
Author(s):  
Erry Yulian Triblas Adesta ◽  
Muataz Al Hazza ◽  
Delvis Agusman ◽  
Agus Geter Edy Sutjipto
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Hard Turning ◽  
Cost Model ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Predictive Regression ◽  
Aisi 4340

The current work presents the development of cost model for tooling during high speed hard turning of AISI 4340 hardened steel using regression analysis. A set of experimental data using ceramic cutting tools, composed approximately of Al2O3 (70%) and TiC (30%) on AISI 4340 heat treated to a hardness of 60 HRC was obtained in the following design boundary: cutting speeds (175-325 m/min), feed rate (0.075-0.125 m/rev), negative rake angle (0 to -12) and depth of cut of (0.1-0.15) mm. The output data is used to develop a new model in predicting the tooling cost using in terms of cutting speed, feed rate, depth of cut and rake angle. Box Behnken Design was used in developing the model. Predictive regression model was found to be capable of good predictions the tooling cost within the boundary design.

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

Analysis of Tool Wear—Part I: Theoretical Models of Flank Wear

1969 ◽  
Vol 91 (3) ◽  
pp. 790-796 ◽  
Author(s):  
A. Bhattacharyya ◽  
I. Ham
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Tool Material ◽  
High Strength ◽  
Theoretical Models ◽  
Flank Surface ◽  
Form Stability ◽  
Sufficient Strength

Cutting tools of sufficient strength against failure by brittle fracture or loss of “form stability” through rise of interface temperatures, still continue to fail by a process of “wear,” which is loss of cutting tool material through gradual interaction between the work and the tool material. Such wear can take place either at the principal flank surface or at the top face of the cutting tool for roughing and semiroughing cuts. Wear may also occur at the auxiliary flank surface resulting in grooving wear during fine machining or machining of high strength materials. The causes for such wear processes include (i) mechanical interaction (abrasion or adhesion and transfer type), (ii) thermochemical interaction (diffusion or chemical reaction). As a part of this investigation on tool wear, two theoretical models have been proposed for explaining mechanical wear at the flank surface. These models explain the nature and characteristics of wear growth and the sensitiveness and dependence of interaction phenomena between the tool-work pair.

Tribological and Thermal Effects of Cutting Fluid Application in Machining With Coated and Grooved Cutting Tools

2005 ◽  
Author(s):  
Anshu D. Jayal ◽  
A. K. Balaji
Keyword(s):  
Cutting Tools ◽  
Chip Morphology ◽  
Cutting Fluid ◽  
Machining Performance ◽  
Chip Breaking ◽  
Tool Coatings ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Application Methods ◽  
1045 Steel

The use of Cutting Fluids (CFs) in machining operations is being increasingly questioned in recent years for environmental and economic reasons, leading to efforts in promoting dry, as well as minimal quantity of lubricant (MQL), machining. However, the tribological effectiveness and thermal aspects of CF action at modern cutting conditions, which not only involve relatively high cutting speeds but also advanced tool coatings and chip-breaking geometric features, need better understanding. This paper presents an experimental investigation into the effects of different CF application methods on various machining performance measures while cutting with commercially available flat-faced, as well as grooved, uncoated and coated cemented tungsten carbide tools. CF effects under dry, flood, and MQL conditions, were gauged through their influence on cutting forces, tool temperatures, tool-chip interfacial contact, and chip morphology during machining of AISI 1045 steel. The results show new trends on the individual cooling and lubricating effects of CF application methods, and the effects of their interactions with the tool coatings and the presence/absence of chip-breaking grooves.

Assessment of the Performance of Microbumped Cutting Tool in Machining of AISI 1045 Steel

2014 ◽  
Author(s):  
J. Ma ◽  
Nick H. Duong ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Tools ◽  
Contact Length ◽  
Machining Performance ◽  
Edge Distance ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

This paper investigates the performance of microbump textured cutting tool in dry orthogonal machining of mild steel (AISI 1045 steel) using AdvantEdge finite element simulation. Microbumps are designed on the rake face of cemented carbide (WC/Co) cutting inserts. The purpose is to examine the effect of microbump textured tools on machining performance and to compare it with non-textured regular cutting tools. Specifically, the following microbump parameters are examined: microbump width, microbump height, and edge distance (the distance from cutting edge to the first microbump). Their effects are assessed in terms of the main force, thrust force, and chip-tool contact length. It is found that microbump textured cutting tools generate lower cutting force and thrust force and consequently lower the energy consumption for machining. The micobump width, microbump height, and edge distance all have influence on cutting force in their own ways.

Wear Mechanism of Ti(C, N)-Based Cermet Cutting Tools in the Machining of Normalized Medium Carbon Steel AISI1045

2007 ◽  
Vol 353-358 ◽  
pp. 792-795 ◽  
Author(s):  
Zeng Min Shi ◽  
Yong Zheng ◽  
Wen Jun Liu
Keyword(s):  
Carbon Steel ◽  
Wear Mechanism ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Vacuum Sintering ◽  
Medium Carbon

Ti(C, N)-based cermet cutting tools were prepared by vacuum sintering and tested in dry machining of normalized medium carbon steel (AISI1045) at various combinations of cutting speed (Vc), feed rate (f), and depth of cut (ap). And the wear mechanism was investigated in detail using scanning electron microscopy (SEM) and electron-probe microanalysis (EPMA). Comparing to the cemented carbide YT15 and cermet TN20, the newly fabricated cermet tools exhibited better performance and higher wear resistance. For Ti(C, N)-based cermet tools, the wear mechanism was predominantly controlled by the flank wear under all cutting condition. It was found that the removal of the ceramic grain and abrasive wear were the main source of tools failure. In addition, adhesion and oxidation were also observed.

scholarly journals Selection of Machining Parameters Using a Correlative Study of Cutting Tool Wear in High-Speed Turning of AISI 1045 Steel

2018 ◽  
Vol 2 (4) ◽  
pp. 66 ◽  
Author(s):  
Luis Hernández González ◽  
Yassmin Seid Ahmed ◽  
Roberto Pérez Rodríguez ◽  
Patricia Zambrano Robledo ◽  
Martha Guerrero Mata
Keyword(s):  
High Speed ◽  
Manufacturing Industry ◽  
Cutting Tool ◽  
Flank Wear ◽  
Machining Parameters ◽  
High Speed Turning ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The manufacturing industry aims to produce many high quality products efficiently at low cost, thereby motivating companies to use advanced manufacturing technologies. The use of high-speed machining is increasingly widespread; however, it lacks a deep-rooted knowledge base needed to facilitate implementation. In this paper, response surface methodology (RSM) has been applied to determine the optimum cutting conditions leading to minimum flank wear in high-speed dry turning on AISI 1045 steel. The mathematical models in terms of machining parameters were developed for flank wear prediction using RSM on the basis of experimental results. The high speed turning experiments were carried out with two coated carbide and a cermet inserts using AISI 1045 steel as work material at different cutting speeds and machining times. The models selected for optimization were validated through the Pareto principle. Results showed the GC4215 insert to be the most optimal option, because it did not reach the cutting tool life limit and could be used for the whole range of cutting parameters selected. To quantitatively evaluate the usefulness of the cutting tools, it was proposed the coefficient of use of the tools from the results of the contour graphs. The GC4215 insert showed 100% effectiveness, followed by the GC4225 with 98.4%, and finally, the CT5015 insert with 83%.

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