An Analysis of Tool Life Based on Flank-Face Wear—Part 2: Comparison of Theory With Experimental Observations

1976 ◽  
Vol 98 (1) ◽  
pp. 227-232 ◽  
Author(s):  
C. Rubenstein
Keyword(s):  
Experimental Evidence ◽  
Tool Life ◽  
Flank Wear ◽  
Large Body ◽  
Cutting Conditions ◽  
Subsurface Layers ◽  
Flank Face

In Part 1 of this paper (Paper No. 75-WA/Prod-28) an analysis of tool life based on a flank-wear criterion was made based on the hypothesis that there exists a range of cutting conditions within which the temperature of the subsurface layers of the workpiece are virtually unaffected while the temperature of the subsurface layers of the tool rises considerably. In the present paper a large body of published experimental evidence is adduced and shown to be consistent with the results of the analysis and, thus, lends support to the hypothesis on which the analysis is based.

On the Measurement and Propagation of Flank Wear in Cutting Tools

1979 ◽  
Vol 101 (2) ◽  
pp. 109-115 ◽  
Author(s):  
M. M. Tseng ◽  
R. A. Noujaim
Keyword(s):  
Adaptive Control ◽  
Tool Wear ◽  
Tool Life ◽  
Conversion Factor ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
No Conversion ◽  
Flank Face

More than three hundred flank wear profiles of carbide cutting tools were digitized, stored and analyzed. It was found that different measures of the same wear zone, such as averages or maximums including or excluding the grooves, can significantly change the out-come of tool life studies. For a given test, all the measures used in this study correlate strongly with the true overall wear average during the entire tool life. However, no conversion factor independent of cutting conditions could be found for these measures. Propagation of tool wear profiles was also analyzed. It revealed that aside from the groove zones, the entire flank face shows equal significance in describing tool wear. Thus, when a wear sensor is physically embedded on the flank face for adaptive control purposes, any location between the grooves is as good as any other.

Tool Wear in Ball-End Milling of Cr12MoV Die Steel Using an Indexable Cutter with the Asymmetric Inserts

2012 ◽  
Vol 500 ◽  
pp. 111-116
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Xin Qiang Zhuang ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Die Steel ◽  
Ball End Milling ◽  
Diffusion Wear ◽  
Flank Face ◽  
And Diffusion

Tool wear was investigated at the different cutting conditions in rough ball-end milling of Cr12MoV die steel using an indexable cutter with asymmetric inserts. The wear patterns on rake face and flank face of major insert and minor insert, and chip patterns were observed by VHX-600E large depth-of-view 3-D scanner. The relationships of tool wear and cutting conditions, and their mechanisms were discussed. The tool life was determined by the flank wear at No. 1 cutting condition. At Nos. 2-8 cutting conditions, the life of major inset and minor insert were determined by the wear of their rake faces and flank faces respectively. At No. 8 cutting condition, the tool wear was dominated by boundary wear, adhesion and diffusion wear, and the slight chipping. Both type and color of chips identified the cutting stability at the different cutting conditions.

scholarly journals Performance of Near Dry Hard Machining Through Pressurised Air Water Mixture Spray Impingement Cooling Environment

2019 ◽  
Vol 16 (1) ◽  
pp. 6108-6133
Author(s):  
R. Kumar ◽  
A.K. Sahoo ◽  
P.C. Mishra ◽  
R.K. Das
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Water Mixture ◽  
Impingement Cooling ◽  
Aisi D2 ◽  
Spray Impingement

The present paper emphasizes on experimental investigation, mathematical modelling, optimisation, tool life and cost analysis during machining of AISI D2 (heat treated) (55±1 HRC) steel using uncoated carbide tool through a novel method under spray impingement cooling environment. Taguchi based L16 orthogonal array was utilised to conduct the experiments. Analysis of variance with 95% confidence level shows that the feed and depth of cut, are the most compelling factor towards surface roughness as well as chip reduction coefficient whereas cutting speed is the utmost compelling feature associated to flank wear as well as chip-tool interface temperature. Optimised result is identified as v1-f1-d1 (machining speed of 63 m/min; cutting feed of 0.04 mm/rev and depth of cut of 0.1 mm) based on grey relational analysis and tool life is found to be 15 minutes at optimised cutting conditions. Flank wear due to abrasion, catastrophic failure due to diffusion, chipping and notch wear are noticed as the major tool wear mechanisms in hard turning. Mathematical machinability models show statistically significance because due to the superior coefficient of correlations. As the global machining cost for each part is less, uncoated carbide tools can machine effectively, efficiently and economically at optimum cutting conditions under spray environment.

Machining nickel base superalloys: Inconel 718

1998 ◽  
Vol 212 (3) ◽  
pp. 195-206 ◽  
Author(s):  
I A Choudhury ◽  
M A El-Baradie
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Coated Tools ◽  
Nickel Base ◽  
Better Than

A series of machining experiments of Inconel 718 has been carried out using coated and uncoated carbides. The paper describes the effects of cutting variables (speed, feed and depth of cut) on cutting forces and tool life. Carbide tools in the form of 80° rhomboid shaped inserts without any chip breaker have been used at different cutting conditions. The machining parameters have been optimized by measuring cutting forces. Flank wear was considered as the criterion for tool life. A comparison between the uncoated and coated tools has been made using the Taylor's tool life exponents of speed, feed and depth of cut. The tool life of coated tools was not found to be better than that of the uncoated tools.

Monitoring of Wear Land Width of Diamond Tool Cutting Edge with Large Nose Radius in Ultra-Precision Cutting Using Static Cutting Forces

2014 ◽  
Vol 1017 ◽  
pp. 696-702
Author(s):  
Eiji Kondo ◽  
Ryuichi Iwamoto ◽  
Yuya Kobaru
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Diamond Tool ◽  
Flank Wear ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Nose Radius ◽  
Single Crystal Diamond ◽  
Ultra Precision ◽  
Land Width

Large wear of diamond tools for ultra-precision cutting of soft metals deteriorates quality of machined surface, and the worn tools have to be replaced with new tools when the tool wear reaches limited wear land width of cutting edge generating finished surface. However, it is difficult to predict the tool life since all cutting tools have individual tool life. Therefore, the purpose of this study is to estimate wear land width of cutting edge of a single crystal diamond tool having large nose radius by using static cutting forces during machining. As a result of the cutting tests and measurements, it was found that the ratio of thrust force to principal force had good relation with the ratio of flank wear land area to cutting cross section area. Furthermore, according to some detailed observation of flank wear, width of flank wear land was greatly related to uncut chip thickness obtained under different cutting conditions and it was found that width of flank wear land could be estimated by measured static cutting forces and cutting conditions.

Performances of Carbide Tools in Machining 18-8 Stainless Steel

1961 ◽  
Vol 83 (4) ◽  
pp. 572-578 ◽  
Author(s):  
H. Takeyama
Keyword(s):  
Stainless Steel ◽  
High Temperature ◽  
Austenitic Stainless Steel ◽  
Tool Life ◽  
Work Hardening ◽  
Flank Wear ◽  
Cutting Conditions ◽  
Optimum Cutting

The austenitic 18-8 stainless steel is one of the most troublesome materials to be machined because of the tendencies of work-hardening, high temperature, and adhesion. The ultimate object of the experiment is to establish the machining standard of the austenitic stainless steel with carbide tools based upon tool life. Generally speaking, tool life in a modern machining practice should be specified not only by the flank wear, but by the crater. This paper describes the process of obtaining the optimum cutting conditions for turning the stainless steel from the viewpoint of tool life, and discusses how the tool life is governed by flank wear and crater depending upon the cutting conditions.

Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

2014 ◽  
Vol 800-801 ◽  
pp. 191-196
Author(s):  
Bin Zhao ◽  
Han Lian Liu ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Hong Tao Zhu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Nickel Based Superalloy ◽  
Coated Tool ◽  
Optimal Cutting Parameters ◽  
Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

scholarly journals Machinability of Nodular Cast Irons : Tool Life and Variation in Tool Forces with Flank Wear

1963 ◽  
Vol 6 (24) ◽  
pp. 823-832
Author(s):  
Katsundo HITOMI ◽  
Inyong HAM ◽  
George L. THUERING
Keyword(s):  
Tool Life ◽  
Flank Wear ◽  
Cast Irons

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

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