Machinability of Nodular Cast Irons: Part II—Effect of Cutting Conditions on Flank Adhesion

1962 ◽  
Vol 84 (2) ◽  
pp. 282-288 ◽  
Author(s):  
K. Hitomi ◽  
G. L. Thuering
Keyword(s):  
Cast Iron ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Nodular Cast Iron ◽  
Rake Angle ◽  
Cutting Conditions ◽  
Cast Irons ◽  
Tool Force ◽  
Iron Grade ◽  
Steel Cutting

To determine the effects of cutting conditions on flank adhesion, nodular cast iron grade 60 was machined dry and wet with carbide cutting tools K6, cast iron cutting grade, and K4H, steel cutting grade. Decreasing the feed rate raised the critical cutting speed at which flank build-up occurred and lowered the resultant tool force. For tools with positive rake angle, the critical cutting speed was generally higher and tool forces were lower than for tools with negative rake angle. A clearance angle of 15 deg eliminated flank adhesion, as did the use of cutting fluids. Flank build-up was analyzed chemically and metallurgically. Methods to prevent flank adhesion are recommended.

On the Effects of a Built-Up Edge on Acoustic Emission in Metal Cutting

1990 ◽  
Vol 112 (2) ◽  
pp. 184-189 ◽  
Author(s):  
D. V. Hutton ◽  
Qinghuan Yu
Keyword(s):  
Acoustic Emission ◽  
Experimental Evidence ◽  
Deformation Zone ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Shear Angle ◽  
Cutting Conditions ◽  
Effective Rake Angle

Experimental evidence is presented which indicates that the presence of a built-up edge can significantly affect the generation of acoustic emission in metal cutting. Results for machining SAE 1018 and 4140 steels show that the built-up edge can mask the generally accepted AE-cutting speed relation when cutting tools having small rake angles are used. Under cutting conditions conducive to development of a built-up edge, it is shown that increased acoustic emission is generated as a result of increased effective rake angle and corresponding increase of shear angle in the primary deformation zone. Three distinct types of built-up edge have been observed and classified as immature, periodic, or developed, according to effect on acoustic emission.

Machinability of Nodular Cast Irons: Part I—Tool Forces and Flank Adhesion

1961 ◽  
Vol 83 (2) ◽  
pp. 142-153 ◽  
Author(s):  
I. Ham ◽  
K. Hitomi ◽  
G. L. Thuering
Keyword(s):  
Cast Iron ◽  
Cutting Force ◽  
Cutting Tools ◽  
High Strength ◽  
Nodular Cast Iron ◽  
Gray Cast ◽  
Cast Irons ◽  
Gray Cast Irons

Three grades of nodular cast iron (60, 80, and 100) were tested to determine the cutting and feed forces required to machine the materials, to determine the performance of several grades of carbide and oxide cutting tools, and to investigate the flank adhesion phenomenon. Cutting characteristics for grade 80 and grade 100 were found to be the same as for high-strength gray cast irons with similar Bhn values. Flank adhesion, with accompanying sharp increases in cutting force values, was encountered only when grade 60 was machined with carbide tools. An attempt was made to correlate tool composition and flank adhesion.

Machinability of Nodular Cast Irons: Part III—Tool Life of Carbide and Ceramic Cutting Tools

1964 ◽  
Vol 86 (2) ◽  
pp. 141-149 ◽  
Author(s):  
K. Hitomi ◽  
G. L. Thuering
Keyword(s):  
Cast Iron ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Nodular Cast Iron ◽  
Cast Irons ◽  
Tool Materials ◽  
Ceramic Cutting Tool ◽  
High Speeds ◽  
Cutting Tool Materials

Three grades of nodular cast iron (60, 80, and 100) were tested to determine the tool life of carbide and ceramic cutting tool materials. Tool life for all tools was much greater for grade 60 than for 80 and 100. Cast iron cutting grade carbide K6 was superior to steel cutting grade K3H, and at high speeds the ceramic was superior.

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 Experiments in the Machining of Ice at Negative Rake Angles

1984 ◽  
Vol 30 (104) ◽  
pp. 77-81 ◽  
Author(s):  
D.K. Lieu ◽  
C.D. Mote
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Orthogonal Machining ◽  
Cutting Force Components ◽  
Force Components

AbstractThe cutting force components and the cutting moment on the cutting tool were measured during the orthogonal machining of ice with cutting tools inclined at negative rake angles. The variables included the cutting depth (< 1 mm), the cutting speed (0.01 ms−1to 1 ms−1), and the rake angles (–15° to –60°). Results of the experiments showed that the cutting force components were approximately independent of cutting speed. The resultant cutting force on the tool was in a direction approximately normal to the cutting face of the tool. The magnitude of the resultant force increased with the negative rake angle. Photographs of ice-chip formation revealed continuous and segmented chips at different cutting depths.

scholarly journals PRELIMINARY STUDY ON EFFECT OF ROD GEOMETRY IN FHPP BETWEEN FE55006 NODULAR CAST IRON AND SAE 8620 STELL

2019 ◽  
Vol 16 (31) ◽  
pp. 642-650
Author(s):  
Douglas MARTINAZZI ◽  
Guilherme V. B LEMOS ◽  
Renan M LANDELL ◽  
Diogo T BUZZATTI ◽  
André BRUSIUS ◽  
...  
Keyword(s):  
Cast Iron ◽  
Base Material ◽  
Nodular Cast Iron ◽  
Lower Surface ◽  
Fusion Welding ◽  
Plastic State ◽  
Cast Irons ◽  
Preliminary Study ◽  
Sae 8620 Steel ◽  
Made In

Nodular cast irons are an excellent alternative in manufacturing process of axels due to their characteristics and good mechanical properties. However, the necessity of joining the axels to the gears and other components, made in carbon steel, is a great challenge. Traditional fusion welding methods applied to dissimilar ferrous materials are not deeply studied. In this context, it is well known that different materials have distinct melting points which can cause difficulty in welding, besides of defects formation from solidification. Therefore, modern joining processes such as Friction Hydro Pillar Processing (FHPP) are a great alternative. In this technology, a consumable rod is rotated against to a base material, generating the heat due to the friction, promoting materials in the plastic state and then producing the weld. Hence, this work presents a preliminary study of FHPP between the FE55006 nodular cast iron and SAE 8620 steel and evaluates the rod geometry influence on microstructure and surface stresses of the welded joints. Two rod geometries were used and two welds were further produced. The results indicated that an increase in the rod contact area promoted a lower surface stress as well as a better welded joint.

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.

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