A Study of Wear on Cemented Carbide Cutting Tools

1969 ◽  
Vol 91 (3) ◽  
pp. 652-658 ◽  
Author(s):  
T. C. Hsu¨
Keyword(s):  
Wear Rate ◽  
Flank Wear ◽  
Cutting Tools ◽  
Specific Wear Rate ◽  
Crater Wear ◽  
Unit Distance ◽  
Steel Bars ◽  
Machinability Index ◽  
Tungsten Carbide Tool ◽  
Effect Of Surface

A technique is developed for measuring accurately the flank wear by using polished tungsten carbide tool tips. The technique is applied to the study of the variation of machinability in mild steel bars and of the possible effect of surface finish of tool face on the wear rate. The specific wear rate, which is the volume of material worn away per unit contact area per unit distance of rubbing, is used to analyze the results on flank wear in this investigation and Trent’s results on crater wear. The constants in an equation representing Trent’s results and in Taylor’s equation for tool life are shown to have physical meanings and to be related to the specific wear rate. The reciprocal of the specific wear rate may be used as a machinability index.

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.

A Cobalt Diffusion Based Model for Predicting Crater Wear of Carbide Tools in Machining Titanium Alloys

2005 ◽  
Vol 127 (1) ◽  
pp. 136-144 ◽  
Author(s):  
Jiang Hua ◽  
Rajiv Shivpuri
Keyword(s):  
Wear Rate ◽  
Titanium Alloys ◽  
High Speed ◽  
Cutting Tools ◽  
Interface Temperature ◽  
Wear Model ◽  
Crater Wear ◽  
Wear Rates ◽  
Process Comparison ◽  
Thermally Driven

In machining titanium alloys with cemented carbide cutting tools, crater wear is the predominant wear mechanism influencing tool life and productivity. An analytical wear model that relates crater wear rate to thermally driven cobalt diffusion from cutting tool into the titanium chip is proposed in this paper. This cobalt diffusion is a function of cobalt mole fraction, diffusion coeficient, interface temperature and chip velocity. The wear analysis includes theoretical modeling of the transport-diffusion process, and obtaining tool–chip interface conditions by a nonisothermal visco-plastic finite element method (FEM) model of the cutting process. Comparison of predicted crater wear rate with experimental results from published literature and from high speed turning with WC/Co inserts shows good agreement for different cutting speeds and feed rate. It is seen that wear rates are independent of cutting time.

Wear Rate of CBN Cutting Tool in Hard Turning of 100Cr6 Bearing Steel

2013 ◽  
Vol 581 ◽  
pp. 50-54
Author(s):  
László Ráczkövi
Keyword(s):  
Wear Rate ◽  
Hard Turning ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Significant Proportion ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Average Wear ◽  
Cutting Speeds

The examination of wear and tool life of CBN cutting tools which are used for hard turning is a emphasized research theme, since the significant proportion of cost of machining associated with cutting tool. In this article we examined the wear of low CBN content cutting tool in case of hard turning of 100Cr6 bearing steel (HRC=62±2). The experiments were carried out with constant depth of cut and feed rate at three different cutting speeds. The flank wear of CBN inserts were measured after predetermined number of passes. The measured flank wear values were described as a function of cutting time and the calculated wear rate as a function of flank wear.The average wear rate were shown at three different cutting speeds.

scholarly journals Comparative Study on the Performance of ZTA Cutting Tool with the Addition of Different Particle Size of MgO Additive

2020 ◽  
Vol 1010 ◽  
pp. 181-186
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Hanani Hani Mohd. Khairy ◽  
Nur Khairunnisa Mohd. Zaki ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Hanisah Manshor ◽  
...  
Keyword(s):  
Particle Size ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Experimental Result ◽  
Machining Parameters ◽  
Crater Wear ◽  
Matlab Programming

This paper investigated the performance of ZTA cutting tool with the addition of different particle size of MgO additive. Therefore, the objective of this research is to compare the effects of machining parameters on tool wears of ZTA cutting tools added with micro and nanoparticle of MgO. The experiments were conducted using BridgePort-Romi Powerpath CNC machine using a tool holder Sandvik Coromant (CoroTurn CCLNR 164D-4) to hold the cutting tools properly. The parameters are set up as cutting speeds used between range 354 to 472 m/min, feed rate from 0.1 to 0.5 mm/rev with a constant depth of cut of 0.2 mm. Three types of wear were analyzed which are flank wear, crater wear and tool chipping. Flank wear and crater wear images captured using measuring microscope (NIKON MM-400/L) and the crater wear areas are analyzed using MatLab programming software. Tool chipping is observed via SEM (JEOL JSM-5600). The experimental result shows that flank wear and crater wear increase when cutting speed and feed rate increase. ZMN cutting tool shows lower value of flank wear at 0.143 mm and 3.741 mm2 for crater wear than ZMM, 0.321 mm and 3.808 mm2 respectively. On the contrary, cutting speed did not affect the tool chipping severely as feed rate. Moreover, ZMN also shows that the tool breakage occurred severely than ZMM due to the high load on the tool nose.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

scholarly journals The Performance of Polycrystalline Diamond (PCD) Tools Machined by Abrasive Grinding and Electrical Discharge Grinding (EDG) in High-Speed Turning

2021 ◽  
Vol 5 (2) ◽  
pp. 34
Author(s):  
Guangxian Li ◽  
Ge Wu ◽  
Wencheng Pan ◽  
Rizwan Abdul Rahman Rashid ◽  
Suresh Palanisamy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Flank Wear ◽  
Polycrystalline Diamond ◽  
Machining Efficiency ◽  
Crater Wear ◽  
Wear Process ◽  
High Speed Turning ◽  
Tools Wear ◽  
Pcd Tools

Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are utilized to manufacture PCD tools. In contrast, electrical discharge grinding (EDG) has significantly higher machining efficiency because of its unique material removal mechanism. In this study, the quality and performance of PCD tools machined by abrasive grinding and EDG were investigated. The performance of cutting tools consisted of different PCD materials was tested by high-speed turning of titanium alloy Ti6Al4V. Flank wear and crater wear were investigated by analyzing the worn profile, micro morphology, chemical decomposition, and cutting forces. The results showed that an adhesive-abrasive process dominated the processes of flank wear and crater wear. Tool material loss in the wear process was caused by the development of thermal cracks. The development of PCD tools’ wear made of small-sized diamond grains was a steady adhesion-abrasion process without any catastrophic damage. In contrast, a large-scale fracture happened in the wear process of PCD tools made of large-sized diamond grains. Adhesive wear was more severe on the PCD tools machined by EDG.

scholarly journals Influence of Test Conditions on Sliding Wear Performance of High Velocity Air Fuel-Sprayed WC–CoCr Coatings

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 3074
Author(s):  
Kaveh Torkashvand ◽  
Vinod Krishna Selpol ◽  
Mohit Gupta ◽  
Shrikant Joshi
Keyword(s):  
Wear Rate ◽  
Test Performance ◽  
Sliding Wear ◽  
Normal Load ◽  
Specific Wear Rate ◽  
Wear Behaviour ◽  
Wear Performance ◽  
Test Conditions ◽  
Test Parameters ◽  
Sliding Distance

Sliding wear performance of thermal spray WC-based coatings has been widely studied. However, there is no systematic investigation on the influence of test conditions on wear behaviour of these coatings. In order to have a good understanding of the effect of test parameters on sliding wear test performance of HVAF-sprayed WC–CoCr coatings, ball-on-disc tests were conducted under varying test conditions, including different angular velocities, loads and sliding distances. Under normal load of 20 N and sliding distance of 5 km (used as ‘reference’ conditions), it was shown that, despite changes in angular velocity (from 1333 rpm up to 2400 rpm), specific wear rate values experienced no major variation. No major change was observed in specific wear rate values even upon increasing the load from 20 N to 40 N and sliding distance from 5 km to 10 km, and no significant change was noted in the prevailing wear mechanism, either. Results suggest that no dramatic changes in applicable wear regime occur over the window of test parameters investigated. Consequently, the findings of this study inspire confidence in utilizing test conditions within the above range to rank different WC-based coatings.

Innovative approach to evaluate the wearing of nano TiO2 doped alumina ceramics in the light of image modelling

2021 ◽  
pp. 1-17
Author(s):  
Partha Haldar ◽  
Alok Mukherjee ◽  
Tapas Kumar Bhattacharya ◽  
Nipu Modak
Keyword(s):  
Wear Rate ◽  
Wear Track ◽  
Specific Wear Rate ◽  
Edge Density ◽  
Alumina Ceramics ◽  
Nano Tio2 ◽  
Image Histogram ◽  
Wide Range ◽  
Density Index ◽  
Sobel Edge Detection

Abstract The present research is emphasized on the microscopic observation of post wear surface of nano TiO2 doped alumina ceramics to accesses wearing by promising image processing algorithms viz. entropy analysis, Sobel edge detection technique and entropy filtered image histogram analysis in relation to the extent of doping. The experimental results of specific wear rate showed an indicator with the extent of micro fracturing of grains, ploughing of materials and debris formation on the wear track after a long wear cycles in terms of entropy level, edge density index, entropy filtered image and the nature of histogram at different doping level. The lowest value of entropy level and edge density index is shown at the level of 1 wt.% TiO2 doped alumina ceramics due to the presence of low number of granularity and microfracture grains on the wear track causes the lowering of specific wear rate. The histogram of entropy filtered image for 1 wt.% doping is more uniformly distributed with the highest frequency and lowest skewness factor over a wide range of intensity values for 1 wt.% doping.

Wear of Coated Cutting Tool Based on AdvantEdge

2014 ◽  
Vol 551 ◽  
pp. 221-227
Author(s):  
Zhi Qiang Zhang ◽  
Tie Qiang Gang ◽  
Yi Kai Yi
Keyword(s):  
Wear Rate ◽  
Coating Thickness ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Simulation Software ◽  
Machining Process ◽  
Sliding Velocity ◽  
Coating Materials ◽  
Element Simulation ◽  
Coated Tool

In this paper, based on finite element simulation software AdvantEdge, the effects of different coating materials and thickness on the wear of cutting tools during the machining process have been studied. For the tools with coating materials of TiAlN, Al2O3, TiN, TiC, we can calculate the wear rate according to the Usui mathematical model of tool wear, and then consider thickness factor of TiC coating. Because of the lowest thermal conductivity, the workpiece cut by TiC coated tool will soften first and more over cutting time, it result in the lowest wear rate. And with the increase of coating thickness, the effect of "thermal barrier" is more obvious for the relatively thicker coating tool, but the relative sliding velocity between the chip and tool is increasing meanwhile, so a suitable coating thickness is necessary.

Tribological and thermomechanical analysis of CaO (quicklime) particulates filled ZA-27 alloy composites for bearing application

2015 ◽  
Vol 232 (1) ◽  
pp. 20-34 ◽  
Author(s):  
Swati Gangwar ◽  
Amar Patnaik ◽  
IK Bhat
Keyword(s):  
Wear Rate ◽  
Normal Load ◽  
Energy Dispersive Spectrometer ◽  
Thermo Gravimetric Analysis ◽  
Research Work ◽  
Surface Profile ◽  
Specific Wear Rate ◽  
Gravimetric Analysis ◽  
Load Range ◽  
Environment Temperature

This research work investigates friction and wears behaviour of CaO filler / particulate reinforced ZA-27 alloy composites. Pin-on-disk tribometer confining to ASTM G 99 standard with EN-31 hardened steel disc was used to simulate the tribological performance experimentally. The tribological parameters were evaluated over a normal load range of 5–45 N, sliding velocity of 1.047–5.235 m/s., sliding distance of 500–2500 m, environment temperature of 25–45℃ and filler content range of 0–10 wt%. The various alloy composites were fabricated under vacuum environment by high-temperature gravity casting technique. The steady-state specific wear rate and coefficient of friction were evaluated under different boundary conditions and thereafter Taguchi design of experiment methodology was adopted to compute the experimental specific wear rate of the proposed alloy composites. The dynamic mechanical analysis and thermo-gravimetric analysis study were also performed in order to observe the thermal characteristics of the composites at higher temperature. Finally, the surface morphology of the worn samples was performed using field-emission scanning electron microscope to understand the wear mechanism prevailed at rubbing surfaces and then atomic force microscopy analysis was studied to evaluate the surface profile of the worn sample. At the end, energy-dispersive spectrometer analysis was also performed to find out the elemental compositions of the worn alloy composites.

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