Controlled Contact Cutting Tools

1959 ◽  
Vol 81 (2) ◽  
pp. 139-147 ◽  
Author(s):  
B. T. Chao ◽  
K. J. Trigger
Keyword(s):  
Shear Stress ◽  
Surface Finish ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Substantial Reduction ◽  
Cutting Fluids ◽  
Dynamic Shear ◽  
Effective Utilization ◽  
High Speed Cutting

A substantial reduction in power consumption, an increase in tool life, more effective utilization of cutting fluids, and improved surface finish on the machined workpiece have been achieved by suitably controlling the length of tool-chip contact. Reasons for these findings are discussed in terms of basic variables in chip formation mechanics. Artificially restricted contact tools open new avenues for metal cutting research. Machining data obtained with such tools provide further evidence of the invariant behavior of the dynamic shear stress of metals under high-speed cutting conditions, and unfold interesting information on the intricate nature of tool-chip contact.

scholarly journals Experimental Investigation on Effects of MQL on Surface Finish and Tool Wear in Turning of SAE 1018

2018 ◽  
Vol 7 (2) ◽  
pp. 67-69
Author(s):  
Sandeep Kumar ◽  
Sukhpal Singh Chatha ◽  
Rutash Mittal
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Metal Cutting ◽  
Substantial Reduction ◽  
Minimum Quantity Lubrication ◽  
Environmental Safety ◽  
Work Piece ◽  
Cutting Fluids ◽  
Nose Radius ◽  
Machining Processes

In all machining processes, tool wear is a major problem and it leads to tool failure. In metal industries, the use of cutting fluids affects both employee’s health and environmental pollution. But the use of cutting fluids becomes necessary to keep tight tolerances and to maintain the work-piece surface properties without damages. Researchers are trying to reduce the use of coolant lubricant fluids in metal cutting to obtain environmental safety. So, to minimize the use of cutting fluids new cutting techniques are investigated. Minimal quantity of Lubrication (MQL) is a recent technique introduced in machining to obtain less tool wear and environment safety. The minimum quantity lubrication was provided with a spray of mixture of air and vegetable oil at suitable pressure. MQL machining was performed much superior compared to dry and wet machining due to substantial reduction in tool wear and cutting zone temperature and a better surface finish. MQL provides neat and clean environment avoiding health hazards due to smoke, fumes and gases etc. In this study work-piece of SAE 1018 were prepared to investigate their Surface finish under turning with coated tool bits. Wear of nose radius of tool bits were analyzed by SEM which results in less wear in MQL process as compared to flood cooling.

Towards an improvement of performance of TiAlN hard coatings using metal interlayers

2002 ◽  
Vol 750 ◽  
Author(s):  
J. M. Castanho ◽  
M. T. Vieira
Keyword(s):  
Thin Films ◽  
Mechanical Properties ◽  
Shear Stress ◽  
High Speed ◽  
Cutting Tools ◽  
Hard Coatings ◽  
Deformation Mechanisms ◽  
Multilayer Coatings ◽  
High Speed Machining ◽  
High Speed Cutting

ABSTRACTTiAlN sputtered coatings have been used with success in high-speed cutting tools in the last few years. However, the adhesive failures of the coatings refrain its application in more severe wear conditions like as high-speed machining. The assumptions for the present research were based on the hypothesis that thin metal interlayers will behave as shear stress sinkers, which could decrease the delamination of the thin films. In the present work, coatings of TiAlN with thin ductile metallic interlayers (Al, Ti, Cu and Ag) were deposited by reactive d.c. magnetron sputtering. Multilayer coatings with aluminum, titanium and silver interlayers achieve higher adhesion values (70N) than TiAlN monolithic coating (40N). Three and five metal ductile layers contribute to an increase of hardness and Young's modulus without change the residual stresses of the monolithic coating. Contrarily, the introduction of copper layers reduces all the studied mechanical properties of the TiAlN monolithic coatings, which are related to the different deformation mechanisms of the ductile interlayers.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

Hard Nano-Crystalline Coatings for Cutting Tools

2007 ◽  
Vol 567-568 ◽  
pp. 185-188 ◽  
Author(s):  
Miroslav Piska
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Dry Cutting ◽  
Nano Crystalline ◽  
The Right ◽  
Machining Productivity ◽  
Hard Cutting ◽  
Cutting Tool Materials

Modern trends in metal cutting, high speed/feed machining, dry cutting and hard cutting set more demanding characteristics for cutting tool materials. The exposed parts of the cutting edges must be protected against the severe loading conditions and wear. The most significant coatings methods for cutting tools are PVD and CVD/MTCVD today. The choice of the right substrate or the right protective coating in the specific machining operation can have serious impact on machining productivity and economy. In many cases the deposition of the cutting tool with a hard coating increases considerably its cutting performance and tool life. The coating protects the tool against abrasion, adhesion, diffusion, formation of comb cracks and other wear phenomena.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

An Integral Method to Determine Workpiece Flow Stress and Friction Characteristics in Metal Cutting

2015 ◽  
Vol 9 (6) ◽  
pp. 775-781
Author(s):  
Norfariza Wahab ◽  
◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo-Young Kim ◽  
...  
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Machining Parameters ◽  
Friction Characteristics ◽  
High Speed Cutting

In recent times, numerical simulation techniques have been commonly used to estimate and predict machining parameters such as cutting forces, stresses, and temperature distribution. However, it is very difficult to estimate the flow stress of a workpiece and the friction characteristics at a tool/chip interface, particularly during a high-speed cutting process. The objective of this study is to improve the accuracy of the present method and simultaneously determine the characteristics of the flow stress of a workpiece and friction at the cutting edge under a high strain rate and temperature during the cutting process. In this study, the Johnson-Cook (JC) flow stress model is used as a function of strain, strain rate, and temperature. The friction characteristic was estimated by minimizing the difference between the predicted and measured results of principal force, thrust force, and shear angle. The shear friction equation was used to estimate the friction characteristics. Therefore, by comparing the measured values of the cutting forces with the predicted results from FEM simulations, an expression for workpiece flow stress and friction characteristics at the cutting edge during a high-speed cutting process was estimated.

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