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.

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.

scholarly journals Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1628
Author(s):  
Mohd Fathullah Ghazali ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Paweł Pietrusiewicz ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Potential Use

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

On a Novel Tool Life Relation for Precision Cutting Tools

2005 ◽  
Vol 127 (2) ◽  
pp. 328-332 ◽  
Author(s):  
A. G. Mamalis ◽  
J. Kundra´k ◽  
M. Horva´th
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
Ultraprecision Machining ◽  
Wear Process ◽  
Tool Materials ◽  
Wide Range

When using new, very expensive superhard tool materials (diamond or CBN) for precision and ultraprecision machining of parts made, very often, from expensive materials, exact knowledge of the tool wear process (considering, of-course, its stochastic character) is absolutely necessary. It means, that we need new tool-life equations for these new tools. In the present paper, a new tool life relation is proposed based on machining experiments. It reflects the two-extremum form of tool life curves and is valid for a wide range of cutting conditions.

Cutting Tool Wear and Mechanisms of Chip Formation During High-Speed Machining of Compacted Graphite Iron

2007 ◽  
Author(s):  
Niniza S. P. Dlamini ◽  
Iakovos Sigalas ◽  
Andreas Koursaris
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Failure Criterion ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Compacted Graphite Iron ◽  
Crater Wear ◽  
Compacted Graphite ◽  
Cutting Speeds

Cutting tool wear of polycrystalline cubic boron nitride (PcBN) tools was investigated in oblique turning experiments when machining compacted graphite iron at high cutting speeds, with the intention of elucidating the failure mechanisms of the cutting tools and presenting an analysis of the chip formation process. Dry finish turning experiments were conducted in a CNC lathe at cutting speeds in the range of 500–800m/min, at a feed rate of 0.05mm/rev and depth of cut of 0.2mm. Two different tool end-of-life criteria were used: a maximum flank wear scar size of 0.3mm (flank wear failure criterion) or loss of cutting edge due to rapid crater wear to a point where the cutting tool cannot machine with an acceptable surface finish (surface finish criterion). At high cutting speeds, the cutting tools failed prior to reaching the flank wear failure criterion due to rapid crater wear on the rake face of the cutting tools. Chip analysis, using SEM, revealed shear localized chips, with adiabatic shear bands produced in the primary and secondary shear zones.

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.

Experimental Study on Tool Wear when Machining Super Titanium Alloys: Ti6Al4V and Ti-555

2013 ◽  
Vol 763 ◽  
pp. 51-64
Author(s):  
Mohammed Nouari ◽  
Hamid Makich
Keyword(s):  
Tool Wear ◽  
Temperature Rise ◽  
Wear Behavior ◽  
Flow Direction ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Wear Process ◽  
Texture Modification ◽  
Wear Modes

To understand the effect of the workpiece microstructure on the tool wear behavior, anexperimental investigation was conducted on machining two different microstructures of supertitanium alloys: Ti-6Al-4V and Ti-555. The analysis of tool-chip interface parameters such asfriction, heat flux and temperature rise and the evolution of the workpiece microstructure underdifferent cutting conditions have been discussed. As cutting speed and feed rate increase, the meancutting forces and temperature show different progressions depending on the consideredmicrostructure. Results show that wear modes for cutting tools used in machining the Ti-555 alloyshow contrast from those exhibited by tools used in machining the Ti6AI4V alloy. In fact, onlyabrasion wear was observed for cutting tools in the case of machining the near-β titanium Ti-555alloy. The last alloy is characterized by a fine-sized microstructure (order of 1 μm). For the usualTi6Al4V alloy, adhesion and diffusion modes followed by coating delamination process on the toolsubstrate have been clearly identified. Moreover, a deformed layer was observed under secondaryelectron microscope (SEM) from the sub-surface of the chip with β-grains orientation along thechip flow direction. The analysis of the microstructure confirms the intense deformation of themachined surface and shows a texture modification, without phase transformation. For the Ti-555β-alloy, β grains experiences more plastic deformation and increases the microhardness of theworkpiece inducing then an abrasion wear process for cemented carbide tools. For the Ti6Al4Vmicrostructure, the temperature rise induces a thermal softening process of the workpiece andgenerates adhesive wear modes for cutting tools. The observed worn tool surfaces confirm theeffect of the microstructure on tool wear under different cutting conditions for the two studiedtitanium alloys.

scholarly journals Additive surface texturing of cutting tools using pulsed laser implantation with hard ceramic particles

2020 ◽  
Vol 14 (5-6) ◽  
pp. 733-742
Author(s):  
S. Böhm ◽  
A. Ahsan ◽  
J. Kröger ◽  
J. Witte
Keyword(s):  
Flank Wear ◽  
Cutting Tools ◽  
Surface Texturing ◽  
Pulsed Laser ◽  
Ductile Cast Iron ◽  
Surface Structures ◽  
Rake Face ◽  
Dry Cutting ◽  
Ceramic Particles ◽  
Flank Face

AbstractIn recent years surface texturing of the cutting tools has proved to improve tribological characteristics at tool/chip and tool/workpiece interface and help to reduce cutting and feed forces as well as tool wear. Most, if not all, of the studies have focused on subtractively made textures whereby the material is removed from the surface. This study investigates the performance of additively made surface structures whereby hard ceramic particles are dispersed in the form of dome shaped textures on the surface of the cutting tools using solid state millisecond pulsed laser (pulsed laser implantation). Dry cutting tests were performed on ductile cast iron. The results show a greater reduction of process forces with implantation of flank face as compared to rake face. Both cutting and feed forces were reduced by 10% compared to the non-structured tool. In addition, the tool life increased by a factor of 3 whereas the average flank wear reduced by as much as 80% and cutting edge rounding by up to 60%.

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

2010 ◽  
Vol 33 ◽  
pp. 173-176
Author(s):  
X.Y. Wang ◽  
S.Q. Pang ◽  
Q.X. Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Experimental Research ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Life Testing ◽  
Processing Efficiency ◽  
Comparative Tests ◽  
Coated Carbide ◽  
Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

Basic Investigation of Tool Wear

1963 ◽  
Vol 85 (1) ◽  
pp. 33-37 ◽  
Author(s):  
H. Takeyama ◽  
R. Murata
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Condition ◽  
Rate Process ◽  
Mechanical Abrasion ◽  
Fundamental Investigation ◽  
First Approximation ◽  
Basic Investigation

This paper treats a fundamental investigation of tool wear and tool life mainly from the viewpoint of flank wear. The result reveals that the mechanism of tool wear in turning can be classified into two basic types: The mechanical abrasion which is directly proportional to the cutting distance and independent of the temperature; and the other is, so to speak, a physicochemical type which is considered to be a rate process closely associated with the temperature, of course. Although it depends upon the cutting condition which type of wear plays a more important role, the latter is predominant under usual conditions. According to the analyses and the experimental results, it has been found out that the tool life from the standpoint of flank wear can be predicted to a first approximation by the initial cutting temperature.

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