Experimental Investigation of Hard Turning Mechanisms by PCBN Tooling Embedded Micro Thin Film Thermocouples

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Linwen Li ◽  
Bin Li ◽  
Xiaochun Li ◽  
Kornel F. Ehmann
Keyword(s):  
Thin Film ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Cutting Insert ◽  
Thin Film Thermocouples ◽  
Cutting Zone

Temperature-distribution measurements in cutting tools during the machining process are extremely difficult and remain an unresolved problem. In this paper, cutting temperature distributions were measured by thin film thermocouples (TFTCs) embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts in the immediate vicinity of the tool-chip interface. The embedded TFTC array provides temperature measurements with a degree of spatial resolution (100 μm) and dynamic response (150 ns) that is not possible with currently employed methods due to the micro-scale junction size of the TFTCs. Using these measurements during hard turning, steady-state, dynamic, as well as chip morphology and formation process analyses were performed based on the cutting temperature and cutting force variations in the cutting zone. It has been shown that the temperature changes in the cutting zone depend on the shearing band location in the chip and the thermal transfer rate from the heat generation zone to the cutting tool. Furthermore, it became evident that the material flow stress and the shearing bands greatly affect not only the chip formation morphology but also the cutting temperature field distributions in the cutting zone of the cutting insert.

Experimental Investigation of Hard Turning Mechanisms by PCBN Tooling Embedded Micro Thin Film Thermocouples

2012 ◽  
Author(s):  
Linwen Li ◽  
Bin Li ◽  
Xiaochun Li ◽  
Kornel F. Ehmann
Keyword(s):  
Thin Film ◽  
Temperature Field ◽  
Temperature Distribution ◽  
Chip Formation ◽  
Hard Turning ◽  
Cutting Temperature ◽  
Temperature Distributions ◽  
Field Distributions ◽  
Thin Film Thermocouples ◽  
Cutting Zone

Temperature-distribution measurements in cutting tools during the machining process are extremely difficult and remain an unresolved problem. In this paper, cutting temperature distributions are measured by thin film thermocouples (TFTCs) embedded into Polycrystalline Cubic Boron Nitride (PCBN) cutting inserts in the immediate vicinity of the tool-chip interface. Using these measurements, steady and dynamic phenomena during hard turning as well as the chip morphology and formation process were analyzed based on the cutting temperature distributions in the insert. The relationship between the cutting temperature-field distributions in the PCBN insert and the segmented chip formation is analyzed using temperature-distribution mapping. It is shown that the temperature-distribution in the cutting zone depends on the shearing band distribution in the chip and the thermal transfer rate from the heat generation zone to the cutting tool. Furthermore, it became evident that the material flow stress and the shearing bands greatly affect not only the chip formation morphology but also the cutting temperature field distributions in the cutting zone of the cutting insert.

Development of Cutting Tools with Built-in Thin Film Thermocouple for Monitoring Machining Temperature

2011 ◽  
Vol 189-193 ◽  
pp. 3170-3174
Author(s):  
Qi Yong Zeng ◽  
Xiao Feng Zheng ◽  
Gao Hui Zhang ◽  
Le Chen
Keyword(s):  
Thin Film ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Vital Role ◽  
Polycrystalline Cubic Boron Nitride ◽  
Thin Film Thermocouple ◽  
Thin Film Thermocouples ◽  
Pcbn Tools ◽  
Deposition Conditions

Temperature plays a vital role in the machining industry today. NiCr/NiSi thin-film thermocouples have been deposited on the rake face of polycrystalline cubic boron nitride (PCBN) tools by magnetron sputtering. The typical deposition conditions are summarized. Static and dynamic calibrations of the NiCr/NiSi thin-film thermocouples are presented. The Seebeck coefficient of the TFTC is 37.3 μV/°C. The response time is about 3.9 ms. The testing results indicate that the developed NiCr/NiSi thin-film thermocouple sensors perform excellently when machining A3 steel in situ.

Comparison between Nitrogen-Oil-Mist and Air-Oil-Mist Condition when Turning of Hardened Tool Stainless Steel

2014 ◽  
Vol 660 ◽  
pp. 18-22
Author(s):  
Mohamed Handawi ◽  
Amad Elddein Issa Elshwain ◽  
Mohd Yusof Noordin ◽  
Norizah Redzuan ◽  
Denni Kurniawan
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Dry Cutting ◽  
Nitrogen Gas ◽  
Cutting Zone ◽  
Oil Mist ◽  
Coated Carbide

Minimum quantity lubrication (MQL) or as it’s called semi dry cutting is a technique which spray a small value of lubricant flow rate to the cutting zone area. MQL has been used in many machining process with different cutting tools and workpiece materials due to its green environments and economically advantageous. MQL has become an attractive option to dry and flood cutting in terms of reduce the temperature in the cutting zone and reduce the cost of the product. However, in MQL seems to be machining limited by cutting temperature, because at high speed the effect of oil mist becomes evaporated. Therefore another alternative cooling approach was used with oil mist in this research. This research presents study the performance of nitrogen gas as a coolant and oil mist as lubricant in turning of hardened stainless tool steel (STAVAX ESR) with hardness 48 HRC. Using a gas as coolant with oil mist is a new solution for enhancing machinability. Turning experiments are carried out on CNC turning machine. The cutting insert grade is KC5010 (PVD-TiAlN wiper coated carbide). The experimental results were: 1) nitrogen gas with oil mist prolongs tool life compare with air with oil mist. 2) better product surface finish by using nitrogen gas with oil mist.

Finite Difference Modeling of Cutting Temperature in Machining of A6061-T6 Aluminum Alloy at Ultra High Cutting Speeds

2007 ◽  
Vol 329 ◽  
pp. 681-686 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Ali Basti ◽  
Jun Shinozuka
Keyword(s):  
Thin Film ◽  
Temperature Distribution ◽  
Finite Difference ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Rake Face ◽  
Thin Film Thermocouples ◽  
Cutting Zone ◽  
The Finite Difference Method ◽  
Cutting Speeds

The finite difference method was applied to simulate temperature distribution in the workpiece, cutting zone and tool in the orthogonal cutting process with multilayer coated sintered alumina tools. The analysis was conducted under different cutting speeds, while experiments were carried out to measure temperatures in different positions of the tool rake face using tools with built-in thin film thermocouples developed by the authors. The temperature distribution calculated along the rake face was consistent with experimental data. This proved that the finite difference modeling developed can be applied to the prediction of cutting temperatures of aluminum alloys for a range of ultra high cutting speeds.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

Machinability of Pearlitic Cast Iron With Cubic Boron Nitride (CBN) Cutting Tools

2002 ◽  
Vol 124 (4) ◽  
pp. 820-832 ◽  
Author(s):  
Jiancheng Liu ◽  
Kazuo Yamazaki ◽  
Hiroyuki Ueda ◽  
Norihiko Narutaki ◽  
Yasuo Yamane
Keyword(s):  
Cast Iron ◽  
Boron Nitride ◽  
Tool Wear ◽  
High Speed ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Conditions ◽  
Machining Center

In order to increase the accurate finishing productivity of pearlitic cast iron, face milling by CBN (Cubic Boron Nitride) cutting tools was studied. The main focus of the study is the machinability investigation of pearlitic cast iron with CBN cutting tools by studying the relationships among machining conditions such as feed rate, cutting speed as well as CBN cutting tool type, tool wear, workpiece surface quality, cutting forces, and cutting temperature. In addition, an emphasis is put on the effect of Al additive in pearlitic cast iron on its machinability and tool wear characteristics. High-speed milling experiments with CBN cutting tools were conducted on a vertical machining center under different machining conditions. The results obtained provide a useful understanding of milling performance by CBN cutting tools.

scholarly journals Tool–Chip Interface Temperature Measurement in Interrupted and Continuous Oblique Cutting

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Sinan Kesriklioglu ◽  
Justin D. Morrow ◽  
Frank E. Pfefferkorn
Keyword(s):  
Cutting Tools ◽  
Protective Layer ◽  
Temperature Data ◽  
Interface Temperature ◽  
Rake Face ◽  
Cutting Insert ◽  
Thin Film Thermocouples ◽  
Cutting Experiment ◽  
Aisi 12L14 ◽  
Cutting Speeds

The objective of this work is to fabricate instrumented cutting tools with embedded thermocouples to accurately measure the tool–chip interface temperature in interrupted and continuous turning. Thin-film thermocouples were sputtered directly onto the flat rake face of a commercially available tungsten carbide cutting insert using micromachined stencils and the measurement junction was coated with a protective layer to obtain temperature data 1.3 μm below the tool–chip interface. Oblique interrupted cutting tests on AISI 12L14 steel were performed to observe the influence of varying cutting speeds and cooling intervals on tool–chip interface temperature. An additional cutting experiment was conducted to monitor the interface temperature change between interrupted and continuous cuts.

Performance Investigation of Modified Turning Tool Holder for MQL Application

2013 ◽  
Vol 465-466 ◽  
pp. 1114-1118
Author(s):  
Erween Abdul Rahim ◽  
Z.H. Samsudin ◽  
Muhammad Arif Abdul Rahim ◽  
Zazuli Mohid
Keyword(s):  
Single Channel ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Tool Holder ◽  
Dual Channel ◽  
Minimal Quantity Lubrication ◽  
Cutting Zone

Some machining process requires coolant to reduce the cutting temperature and helps to flush away the chips from the cutting zone. However, conventional flood coolant possesses some issues towards workers and the environment, regarding health and waste management. The implementation of Minimal Quantity Lubrication (MQL) as an alternative technique seems to be promising although the effectiveness of this technique were influenced by several factor. In turning process for instance, the distance of nozzle to the cutting zone contributes to the variation of machining performance. This study is to compare the effect on cutting performance between two internal MQL nozzle designs. The cutting tool holder were modified to have two internal MQL oil channel. The oil channel design were tested and the performance was evaluated in terms of cutting speed and cutting temperature for different cutting speed, feed rate and depth of cut. The result shows that the single channel performs better in terms of cutting force while dual channel significantly improve the cutting temperature.

scholarly journals Mekanisme Pembentukan Burr pada Pemesinan Frais Mikro Ti 6Al- 4V ELI dalam Keadaan Kering

2020 ◽  
Vol 11 (3) ◽  
pp. 307-312
Author(s):  
Endra Saputra ◽  
◽  
Gusri Akhyar Ibrahim ◽  
Suryadiwansa Harun ◽  
Eko Agus Supriyadi ◽  
...  
Keyword(s):  
High Speed ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Machining Process ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Hard Metals ◽  
Titanium Material ◽  
Cutting Zone

One of the ingredients that are popular now is titanium, but titanium is a material that is difficult to process using conventional milling machining because of the poor thermal conductivity of the material so that the high-temperature machining process produced in the cutting zone causes plastic deformation in cutting tools and increased chemical reactivity in titanium. High-speed micro-milling machining can be used for micromachining of hard metals or alloys that are difficult to achieve at low speeds. Micro milling machining in titanium material 6Al-4V ELI with variations in milling knife diameter 1 and 2 mm, spindle speed 10.000 and 15.000 rpm, feed 0,001 and 0,005 mm / rev, depth of cut 100 and 150 μm, which then do data processing using the method Taguchi full factorial and theoretical analysis. The results showed that the diameter of the tool and into the cut had the greatest effect on burr formation, the greater the diameter of the milling blade resulted in the formation of shorter and smaller burrs, the use of a 1 mm diameter milling blade and a 150 μm depth cut gave rise to long burr formations and tight, while the use of a 2 mm diameter milling blade and a cutting depth of 100 μm give rise to a short and slight burr formation.

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