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.

Tool-Chip Interface Temperature Measurement in Interrupted and Continuous Oblique Cutting

2017 ◽  
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 micro machined stencils and coated the measurement junction 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.

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.

Characterization of Tool–Chip Interface Temperature Measurement With Thermocouple Fabricated Directly on the Rake Face

2019 ◽  
Vol 141 (9) ◽  
Author(s):  
Sinan Kesriklioglu ◽  
Cory Arthur ◽  
Justin D. Morrow ◽  
Frank E. Pfefferkorn
Keyword(s):  
Temperature Measurement ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Smart Manufacturing ◽  
Future Research ◽  
Interface Temperature ◽  
Rake Face ◽  
Serrated Chip ◽  
Cutting Insert

The objective of this work is to fabricate thermocouples directly on the rake face of a commercially available tungsten carbide cutting insert for accurately measuring the tool–chip interface temperature during metal cutting. The thermocouples are sputtered onto the cutting insert using micromachined stencils, are electrically isolated with layers of Al2O3, and receive a top coating of AlTiN for durability. The result is a nonsacrificial thermocouple junction that is approximately 1.3 µm below the rake face of the tool and 30 µm from the cutting edge. Experimental and numerical characterization of the temperature measurement accuracy and response time are presented. The instrumented cutting tool can capture the tool–chip interface temperature transients at frequencies of up to 1 MHz, which enables the observation of serrated chip formation and adiabatic shear events. Temperature measurements from oblique machining of 4140 steel are presented and compared with three-dimensional, transient numerical simulations using finite element analysis, where cutting speed and feed are varied. This method of measuring the tool–chip interface temperature shows promise for future research and smart manufacturing applications.

scholarly journals Comparative Analysis of Simulation Results of Hard-to-Cut Materials Machining by Coated Cutting Tools

2020 ◽  
Vol 70 (2) ◽  
pp. 153-166
Author(s):  
Stupnytskyy Vadym ◽  
Xianning She
Keyword(s):  
Wear Resistance ◽  
Comparative Analysis ◽  
System Approach ◽  
Thermal State ◽  
Cutting Tools ◽  
Rake Face ◽  
Friction Behavior ◽  
Wear Resistant Coatings ◽  
Cutting Insert ◽  
Simulation Results

AbstractThe article describes the system approach to simulation the process of machining hard-to-cut materials using tools with wear-resistant coatings. In addition to increasing the wear resistance of the tool, factors such as thermal state model, load parameters and friction behavior at the tool-chip interface have been analyzed. A comparative analysis of these parameters is described in the article. It has been proven that the greatest wear of the cutting edge does not occur on the top of the tool, but in the area where the chip speed along the rake face of the cutting insert is greatest.

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.

STORA ASP 60

Alloy Digest ◽  
1978 ◽  
Vol 27 (12) ◽  
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Heat Treating ◽  
Machine Material ◽  
High Hardenability ◽  
Metallurgy Steel ◽  
Special Steels ◽  
Cutting Speeds ◽  
Hot Hardness

Abstract STORA ASP 60 is a molybdenum-tungsten high-speed steel with high percentages of carbon, cobalt and vanadium. It is a powder metallurgy steel, has high hardenability and can be hardened by cooling in air or oil from the austenitizing temperature. It has an excellent combination of wear resistance, toughness, hot hardness and resistance to tempering. It is recommended for cutting tools for hard-to-machine material and high cutting speeds. This datasheet provides information on composition, physical properties, microstructure, hardness, and elasticity. It also includes information on forming, heat treating, and machining. Filing Code: TS-342. Producer or source: Stora Kopparberg, Special Steels Division.

STORA ASP 30

Alloy Digest ◽  
1978 ◽  
Vol 27 (9) ◽  
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Cobalt Content ◽  
Heat Treating ◽  
Machine Material ◽  
High Hardenability ◽  
Special Steels ◽  
Cutting Speeds ◽  
Hot Hardness

Abstract STORA ASP 30 is a high hardenability tungsten-molybdenum alloyed high-speed steel with high cobalt content. It is recommended for cutting tools for hard-to-machine material and high cutting speeds. It has excellent wear resistance, toughness, hot hardness and resistance to tempering. The excellent size stability and good grindability of ASP 30 make it very suitable for tools with a complicated shape. This datasheet provides information on composition, physical properties, microstructure, hardness, and elasticity. It also includes information on forming, heat treating, and machining. Filing Code: TS-338. Producer or source: Stora Kopparberg, Special Steels Division.

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.

scholarly journals Performance of Volcano-Like Laser Textured Cutting Tools: An Experimental and Simulative Investigation

Lubricants ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 98 ◽  
Author(s):  
Zhengyang Kang ◽  
Yonghong Fu ◽  
Xingyu Fu ◽  
Martin Jun
Keyword(s):  
Cutting Force ◽  
Cutting Tools ◽  
Surface Texturing ◽  
Temperature Fields ◽  
Small Scale ◽  
Rake Face ◽  
Forming Process ◽  
Force Reduction ◽  
And Performance ◽  
Distribution Of Stress

In recent years, surface texturing in micro-scale has been attempted on the surface of cutting tools for multiple purposes, e.g., cutting force reduction, prolonging life-span, anti-adhesion, etc. With respect to machinability and performance, micro-groove texture (MGT) has dominated in this field compared to other textured patterns. In this study, a novel volcano-like texture (VLT) was fabricated on the rake face of cemented carbide inserts (WC-Co, YG6) by fiber laser. The following cutting experiment tested the flat, MGT and VLT tools in turning aluminum alloy 6061. The effects of coolant and cutting conditions were investigated. In addition, a validated FEM model was employed to explore the distribution of stress and temperature fields in the tool-chip interface. The initial forming process of adhesion layer on rake face was investigated as well. The results indicated that lower cutting force and less adhesion can be achieved by small scale VLT. This study not only introduced VLT on cutting tools but also revealed its comprehensive performance.

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