Effect of Stiffness on Tool Wear and New Tool Life Equation

1975 ◽  
Vol 97 (3) ◽  
pp. 939-944 ◽  
Author(s):  
E. Kuljanic´
Keyword(s):  
Statistical Analysis ◽  
Tool Life ◽  
Dynamic Stiffness ◽  
Cutting Speed ◽  
Testing Method ◽  
Number Of Teeth ◽  
Pulse Testing ◽  
Machining System ◽  
Cutting Speeds ◽  
Significant Factors

An investigation of the effect of stiffness of the machining system on tool life with different numbers of teeth in the cutter, cutting speeds, and feeds is described. A statistical analysis was used and the effects of significant factors and interactions were determined. Not only the cutting speed, feed, and number of teeth in the cutter, but also the stiffness and their interactions have a significant effect on tool life. Due to a significant effect of interactions, the effect of the stiffness of machining system depends on the number of teeth in the cutter, cutting speed and feed. A new tool life equation was developed to take this phenomenon in account. The tool life decreases with increasing the number of teeth in the cutter. The static and dynamic stiffness was measured by means of a pulse-testing method which is both simple and reliable in determining the dynamic characteristics of a machining system.

scholarly journals Investigation into Performance of Multilayer Composite Nano-Structured Cr-CrN-(Cr0.35Ti0.40Al0.25)N Coating for Metal Cutting Tools

Coatings ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 447 ◽  
Author(s):  
Sergey Grigoriev ◽  
Alexey Vereschaka ◽  
Alexander Metel ◽  
Nikolay Sitnikov ◽  
Filipp Milovich ◽  
...  
Keyword(s):  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Constructional Steel ◽  
Wear Process ◽  
Layered Architecture ◽  
Process Pattern ◽  
Resistant Layer ◽  
Cutting Speeds

This paper deals with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating. It has a three-layered architecture with a nano-structured wear-resistant layer. The studies involved the investigation into the microstructure (with the use of SEM and TEM), elemental and phase composition (XRD and SAED patterns), wear process pattern in scratch testing, crystal structure, as well as the microhardness of the coating. Cutting tests of tools with the above coating were carried out in dry turning of steel 1045 at cutting speeds of vc = 200, 250, and 300 m·min−1. The comparison included uncoated tools and tools with the commercial TiN and (Ti,Al)N coatings with the same thickness. The tool with the Cr-CrN-(Cr0.35Ti0.40Al0.25)N coating showed the longest tool life at all the cutting speeds under consideration. Meanwhile, a tool with the coating under study can be recommended for use in turning constructional steel at the cutting speed of vc = 250 m·min−1. At this cutting speed, a tool shows the combination of a rather long tool life and balanced wear process, without any threat of catastrophic wear.

scholarly journals Statistical analysis of surface roughness of machined graphite by means of CNC milling

2016 ◽  
Vol 36 (3) ◽  
pp. 89 ◽  
Author(s):  
Orquídea Sánchez López ◽  
Armando Rosas González ◽  
Ignacio Hernández Castillo
Keyword(s):  
Statistical Analysis ◽  
Feed Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Second Order ◽  
Numerical Control ◽  
Cnc Milling ◽  
Cutting Depth ◽  
Significant Factors

The aim of this research is to analyze the influence of cutting speed, feed rate and cutting depth on the surface finish of grade GSP-70 graphite specimens for use in electrical discharge machining (EDM) for material removal by means of Computer Numerical Control (CNC) milling with low-speed machining (LSM). A two-level factorial design for each of the three established factors was used for the statistical analysis. The analysis of variance (ANOVA) indicates that cutting speed and feed rate are the two most significant factors with regard to the roughness obtained with grade GSP-70 graphite by means of CNC milling. A second order regression analysis was also conducted to estimate the roughness average (Ra) in terms of the cutting speed, feed rate and cutting depth. Finally, the comparison between predicted roughness by means of a second order regression model and the roughness obtained by machined specimens considering the combinations of low and high levels of roughness is also presented.

scholarly journals Analysis of the General Tool Life Function of Cutting Tools by Application of the Catastrophe-Theory

2021 ◽  
Author(s):  
Zoltán Pálmai ◽  
János Kundrák ◽  
Csaba Felhő
Keyword(s):  
Tool Life ◽  
Catastrophe Theory ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Taylor Formula ◽  
Technology Planning ◽  
Concave Part ◽  
Cutting Speeds ◽  
General Tool ◽  
Life Function

Abstract Production technology planning requires information on tool life T and its relation to cutting speed v. As the Taylor formula often cannot be linearized on an lg-lg scale, a general tool life function has been developed for describing a v-T function with a convex-concave part. Using catastrophe theory, an analogy is established between the general tool life function and the cusp catastrophe, allowing topological mapping of the general v-T function. Results were verified by machinability tests in the turning of C35 and C60 conventional and specially deoxidized C-steels during steelmaking. It was found that in the convex-concave section of this function, 2–3 cutting speeds can be selected for a given tool life, which is advantageous for harmonizing tool changes in multi-operation technology.

Computerized Determination and Analysis of Cost and Production Rates for Machining Operations: Part 2—Milling, Drilling, Reaming, and Tapping

1969 ◽  
Vol 91 (3) ◽  
pp. 585-596 ◽  
Author(s):  
M. Field ◽  
N. Zlatin ◽  
R. Williams ◽  
M. Kronenberg
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Production Rates ◽  
Optimum Cutting ◽  
The Cost ◽  
Machining Operations ◽  
Cutting Speeds ◽  
Minimum Costs

In Part 1 of this two-part paper, generalized equations for cost and production were presented for five major types of machining operations: turning, milling, drilling, reaming, and tapping. In addition, detailed cost equations were presented for the turning operation for three types of lathe tools: brazed carbide tools, throwaway tools, and solid high-speed steel tools. The present paper, Part 2, presents the detailed cost and production analysis for the remaining machining operations: milling, drilling, reaming, and tapping. Individual equations are developed within each machining category for the major types of cutters and tools involved in the operation. Examples are presented illustrating the use of these equations on specific problems. In addition, equations are developed for calculating the optimum cutting speeds and tool life corresponding to minimum costs and maximum production rates assuming that the tool life-cutting speed follows the simplified Taylor equation. The optimized equations enable one to interpolate and extrapolate the cost and production determinations. Care must be exercised to check experimentally the interpolated or extrapolated values to verify the results from the calculations.

scholarly journals Experimental investigation of the effects of cryogenic cooling on tool life in Ti6Al4V milling

2021 ◽  
Author(s):  
Paolo Albertelli ◽  
Valerio Mussi ◽  
Matteo Strano ◽  
Michele Monno
Keyword(s):  
Tool Life ◽  
Cutting Speed ◽  
Cryogenic Cooling ◽  
Model Parameters ◽  
Cryogenic Milling ◽  
High Cutting Speed ◽  
Cutting Velocity ◽  
Life Tests ◽  
Conventional Cooling ◽  
Cutting Speeds

AbstractIn this paper, the results of an experimental campaign of cryogenic milling are presented and discussed. For this purpose, a specific experimental setup that allowed to feed the liquid nitrogen LN through the tool nozzles was used. Tool life tests were carried out at different cutting speeds. The tool duration data were collected and used to identify the parameters of the Taylor’s model. Different end-of-life criteria for the tool inserts were even investigated. The achieved results are compared to those obtained using conventional cooling. It was observed that at low cutting velocity, conventional cooling still assures longer tool lives than in cryogenic condition. Since in cryogenic milling the increasing of the cutting velocity is not so detrimental as in conventional cutting, at high cutting speed (from 125 m/min) longer tool durations can be achieved. Statistical analyses on the model parameters were carried out to confirm the presented findings. The analysis of the effect of the cooling approach on the main wear mechanisms was also reported. At low cutting speed, adhesion and chipping phenomena affected the tool duration mainly in cryogenic milling.

Performance of carbide tools in high-speed dry turning iron-based superalloys

2021 ◽  
pp. 095440542110285
Author(s):  
Xianhua Tian ◽  
Kuicheng Yan ◽  
Zhi Wang ◽  
Fangwei Xie ◽  
Ya Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Surface Finish ◽  
High Speed ◽  
Cutting Speed ◽  
Rake Face ◽  
Dry Turning ◽  
Coated Tools ◽  
Flank Face ◽  
Iron Based ◽  
Cutting Speeds

Machining quality and productivity of superalloys are limited due to their poor machinability, and fewer studies have focused on the cutting of iron-based superalloys. In this study, the cutting performance of coated and uncoated carbide tools in high-speed dry turning iron-based superalloy GH2132 was investigated by performing a series of cutting experiments. The experimental results indicated that cutting temperature and cutting forces increased, while tool life decreased with the increase in the cutting speed from 30 to 100 m/min. Under relatively low cutting speeds, flank face wear was dominated by abrasion and adhesion, while rake face wear mainly involved built-up edge (BUE), built-up layer (BUL), adhesion, and breakage near the depth of cut. Under higher cutting speed, adhesion wear was more serious on the flank face, and peeling off of the coatings and substrate occurred on the rake face. Owing to the protective effect of (Ti, Al)N + TiN coating, the coated tools exhibited better wear resistance and thus longer tool life, in particular, under higher cutting speeds. Analysis of the tool wear gap in the horizontal direction indicates that better dimensional accuracy could be obtained when coated tools are used. In dry turning of GH2132 with carbide tools, a favorable surface finish could be obtained. The surface roughness roughly showed a tendency to first decrease and then increase with the increase in average flank wear. The coated tools should be avoided to machine GH2132 at higher cutting speed due to the poor surface finish.

Micro Quantity Internal Cooling (MQUIC™) of Cutting Tools for Increased Productivity While Machining Ti-6Al-4V

2010 ◽  
Author(s):  
Samved Bhatnagar ◽  
William J. Endres
Keyword(s):  
Tool Life ◽  
Unit Cost ◽  
Cutting Tools ◽  
Cutting Speed ◽  
High Strength ◽  
Internal Cooling ◽  
Wear Rates ◽  
Industry Standard ◽  
Tool Performance ◽  
Cutting Speeds

Machining of space age materials like Ti-6Al-4V is associated with thermally activated wear mechanisms which lead to rapid tool failure and increased machine downtime. The high strength and low thermal conductivity of Ti-6Al-4V can reduce tool-life significantly at high cutting speeds adding drastically to the per-unit cost. A new concept, Micro Quantity Internal Cooling (MQUIC™) has been developed to extend the tool-life and/or enable higher cutting speeds while machining Ti-6Al-4V. The concept involves introducing flow (coolant) in a micro-duct placed inside the tool and close to the cutting edge, thus bringing the cooling source close to the heat source (chip-contact area). In this research, experiments have been conducted to compare the performance (wear rates) of cutting tools using the MQUIC™ concept with those run under dry or flood conditions. Further, two levels of feed and cutting speed are selected for the experiments so as to be able to investigate the combined effect of parameters on tool performance. Physical testing employing coolant consumption of less than 5% of typical flood coolant rates proves the viability of the concept by demonstrating wear rates of 1/3 to 1/2 those of flood cooling. The testing also proves the application of the MQUIC™ concept to enable higher cutting speeds than the current industry standard for machining Ti-6Al-4V. This paper presents the experimental setup, methodology and results obtained while testing the feasibility of the concept.

Tool Life of Coated Tools in Face Milling of GH4169 at Various Cutting Speeds

2013 ◽  
Vol 770 ◽  
pp. 126-129 ◽  
Author(s):  
Xiang Yu Wang ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Qing Ge Zhang ◽  
Han Lian Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
High Cutting Speed ◽  
Coated Tools ◽  
Life Tests ◽  
Material Tool ◽  
Cutting Speeds

GH4169 is widely used in aerospace industry, and it is a typical difficult-to-cut material. Tool life in cutting GH4169 is very low. In this paper, tool life tests of face milling GH4169 were carried out at 30~90m/min with coated tools. The effects of cutting speed and feed rate on the tool life were studied. It was found that the tool life was very sensitive to the cutting speed. And tool failure mode was flank wear at low cutting speed, but turned to tipping at high cutting speed. At last, the suitable cutting parameters were recommended.

Cutting Tool Life in Machining at Various Speeds

2013 ◽  
Vol 581 ◽  
pp. 38-43 ◽  
Author(s):  
Zoltán Pálmay
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Taylor Formula ◽  
Cutting Speeds

Cutting tool life is usually described by means of the well-known Taylor formula, which originally specifies tool life as a function of cutting speed. That cutting is performed with the same tool at various successive speeds, thereby rendering the Taylor formula is unusable, which is a common problem. In the case of periodically changing cutting speeds it can be verified both theoretically and through experiments that equation Σ∆ti/Ti≈1 is valid. The generalised form of the Taylor formula, which can also be applied for cutting at periodically changing speeds, could be derived from this equation. If cutting is performed at various speeds, an equivalent speed and a corresponding tool life, which can also be handled by means of the traditional Taylor formula, may be specified.

Optimisation of End Milling Machining Parameters Using the Taguchi Method and ANOVA of AlSi/AlN Metal Matrix Composite Material

2016 ◽  
Vol 701 ◽  
pp. 200-204 ◽  
Author(s):  
Mohamad Sazali Said ◽  
Jaharah A. Ghani ◽  
Mohd Asri Selamat ◽  
Nurul Na'imy Wan ◽  
Hassan C.H. Che
Keyword(s):  
Matrix Composite ◽  
Tool Life ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Feed ◽  
Machining Parameter ◽  
Cutting Speeds

Abstract. The purpose of this research is to determine the optimum machining parameter for Aluminium silicon alloy (AlSi) matrix composite, which has been reinforced with aluminium nitride (AlN), with three types of carbide inserts present. Experiments were conducted at various cutting speeds, feed rates and depths of cut, according to the Taguchi orthogonal array L27. The signal-to-noise (S/N) ratio and analysis of variance are applied to study the characteristic performance of cutting speeds, feed rates, depths of cut and types of tool in measuring the tool life during the milling operation. The analysis of wear was done using a Sometech SV-35 video microscope according to ISO 3686. Through Taguchi analysis, it is concluded that a combination of high feed rate, high depth of cut, low cutting speed and insert TiB2 give a longer tool life. Therefore, the cutting speed of 230 m/min, feed rate of 0.8 mm/tooth, depth of cut of 0.5 mm and type of insert of TiB2 were the optimum machining parameters. These optimum parameters will help the automotive industry to have a competitive machining operation from both economical and manufacturing perspectives.

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