Design for Manufacturing of Variable Microgeometry Cutting Tools

2017 ◽  
Vol 140 (1) ◽  
Author(s):  
N. Z. Yussefian ◽  
A. Hosseini ◽  
K. Hosseinkhani ◽  
H. A. Kishawy
Keyword(s):  
Tool Life ◽  
Wedge Angle ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Machining Process ◽  
Valuable Insight ◽  
Machining Parameters ◽  
Workpiece Surface ◽  
Coated Carbide ◽  
Edge Preparation

Cutting edge microgeometry has gained special attention of late in the machining research community. Machine tool vibration, tool life, and workpiece surface integrity are all influenced by cutting edge size/shape. To optimize the machining process, variable microgeometry (VMG) cutting tools, in which the edge microgeometry varies along the edgeline with respect to specific variables (such as machining parameters or expected tool wear), are manufactured. Despite the advantages of VMG tools, a major hindrance in their development is the manufacturing complexity that demands high precision multi-axis edge preparation processes following extensive machine setup, fixturing, and programming. This paper details the proof of concept of a design criterion, which leads to the manufacturing of VMG cutting tools by only traditional edge preparation processes. The present method relies on the existing relationship between the edge radius subsequent to the edge preparation process and the tool wedge angle. The validity of the proposed method is first examined by a numerical simulation of the edge preparation. Carbide cutting tool inserts are then designed based on the proposed idea. Robust VMG generation subsequent to edge preparation by microblasting is demonstrated through microgeometric measurements. VMG chemical vapor deposition-coated carbide tools manufactured by the proposed approach are evaluated for turning hardened steel, and optimal designs are identified with respect to tool life and workpiece surface roughness. To address the design consideration, finite element (FE) modeling provides valuable insight into the machining process. FE modeled stress and temperature distribution clarify the experimental observations and reveal the design constraints.

Kantenpräparation durch Formschleifprozesse*/Cutting edge preparation by form grinding

2017 ◽  
Vol 107 (06) ◽  
pp. 453-460
Author(s):  
E. Prof. Uhlmann ◽  
J. Bruckhoff
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Grinding Processes ◽  
Form Grinding ◽  
Cutting Edge Preparation ◽  
Edge Preparation

Angesichts steigender Anforderungen an Zerspanwerkzeuge nimmt die Schneidkantenpräparation einen immer größer werdenden Stellenwert ein, da sich so die Standzeit von Zerspanwerkzeugen erhöhen lässt. Die bisher eingesetzten Präparationsverfahren eignen sich meist nur für einfache Verrundungen an der Schneidkante. In umfangreichen Untersuchungen wurde die Eignung von Formschleifprozessen zur Herstellung definierter Schneidkantenmikrogeometrien anhand von Arbeitsergebnissen analysiert.   Due to increasing demands on cutting tools cutting edge preparation has a high priority because it influences the tool life. Current cutting edge preparation processes can only generate simple roundings on the cutting edge. By extensive investigations the suitability of form grinding processes for the production of defined microgeometries on the cutting edge was analysed.

Influence of Edge Preparation on Cutting Tool Wear

2012 ◽  
Vol 201-202 ◽  
pp. 1178-1181
Author(s):  
Guo Bing Chai ◽  
Wei Wang ◽  
Ai Bing Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tool ◽  
Impact Resistance ◽  
Cutting Tools ◽  
Medium Carbon Steel ◽  
Cutting Edge ◽  
Cutting Tool Wear ◽  
Edge Radius ◽  
Edge Preparation

Edge preparation is not only the process of grinding proper geometry of cutting edge or removing micro-cracks on cutting edge region, but also a way of improving cutting tool life. In this study, cutting models with different cutting edge radius were set up with FEM software. Medium carbon steel cutting tests were carried out using cutting tools with different edge radius. Cutting tool wear was simulated and measured for comparison. The simulation results show that edge radius has influences on tool wear. Tool cutting behavior is concerned with edge radius. A proper edge radius will improve the tool life. The experimental results show that proper edge preparation could improve tool impact resistance capability and reduce tool wear. The cutting tool life can be prolonged with suitable edge preparation. Edge preparation can improve cutting performance of cutting tool.

scholarly journals The Tool Life and Coating-Substrate Adhesion of AlCrSiN-Coated Carbide Cutting Tools Prepared by LARC with Respect to the Edge Preparation and Surface Finishing

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 166 ◽  
Author(s):  
Tomáš Vopát ◽  
Martin Sahul ◽  
Marián Haršáni ◽  
Ondřej Vortel ◽  
Tomáš Zlámal
Keyword(s):  
Tool Life ◽  
Bias Voltage ◽  
Cutting Edge ◽  
Cemented Carbide ◽  
Surface Finishing ◽  
Cutting Edge Radius ◽  
Substrate Adhesion ◽  
Edge Radius ◽  
Coated Carbide ◽  
Edge Preparation

Nanocomposite AlCrSiN hard coatings were deposited on the cemented carbide substrates with a negative substrate bias voltage within the range of −80 to −120 V using the cathodic arc evaporation system. The effect of variation in the bias voltage on the coating-substrate adhesion and nanohardness was investigated. It was clear that if bias voltage increased, nanohardness increased in the range from −80 V to −120 V. The coating deposited at the bias voltage of −120 V had the highest nanohardness (37.7 ± 1.5 GPa). The samples were prepared by brushing and wet microblasting to finish a surface and prepare the required cutting edge radii for the tool life cutting tests and the coating adhesion observation. The indents after the static Mercedes indentation test were studied by scanning the electron microscope to evaluate the coating-substrate adhesion. The longer time of edge preparation with surface finishing led to a slight deterioration in the adhesion strength of the coating to the substrate. The tool wear of cemented carbide turning inserts was studied on the turning centre during the tool life cutting test. The tested workpiece material was austenitic stainless steel. The cemented carbide turning inserts with larger cutting edge radius were worn out faster during the machining. Meanwhile, the tool life increased when the cutting edge radius was smaller.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

Drehen von ausferritischem Gusseisen*/Turning of austempered ductile iron – Impact of inhomogeneous cutting edge geometry on wear mechanism and machining result

2018 ◽  
Vol 108 (10) ◽  
pp. 736-742
Author(s):  
J. Hartig ◽  
B. Kirsch ◽  
J. Aurich
Keyword(s):  
Tungsten Carbide ◽  
Tool Life ◽  
Wear Mechanism ◽  
Ductile Iron ◽  
Cutting Edge ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Machining Performance ◽  
Edge Geometry ◽  
Homogeneous Preparation

Mit Schneidkantenpräparation kann das Werkzeug im Zerspanprozess an die Bearbeitungsaufgabe angepasst werden. Homogene Präparationen können dabei entweder auf hohe Belastungen des Werkzeugs oder ein optimiertes Bearbeitungsergebnis im Sinne der Oberfläche ausgelegt werden. In diesem Beitrag wurden die Schneidkanten von Hartmetall-Wendeschneidplatten unterschiedlich inhomogen präpariert, um den unterschiedlichen Anforderungen entlang des Eingriffs Rechnung zu tragen. Neben der Werkzeugstandzeit wurde das Prozessergebnis beim Außenlängs-Runddrehen von ausferritischem Gusseisen (ADI) 900 untersucht.   The preparation of cutting edges allows for tools to be tailored to the machining process. A homogeneous preparation can either be designed for high loads in the machining process or an optimized machining result on the surface. In this article, the cutting edges of tungsten carbide indexable inserts were prepared inhomogeneously and thus individually matched to the machining task. Tool life and machining performance while turning austempered ductile iron (ADI) 900 were investigated.

Standzeitoptimierung von Kreissägewerkzeugen/Optimization of the tool life of circular saw blades

2021 ◽  
Vol 111 (11-12) ◽  
pp. 833-839
Author(s):  
Kolb Moritz ◽  
Tim Mayer ◽  
Nico Rasenberger
Keyword(s):  
Service Life ◽  
Tool Life ◽  
Model Test ◽  
Wear Behavior ◽  
Cutting Edge ◽  
Circular Saw ◽  
Single Tooth ◽  
Cutting Edge Preparation ◽  
Saw Blade ◽  
Edge Preparation

Dieser Beitrag beschreibt, wie sich die Standzeit von Kreissägeblättern durch Schneidkantenpräparation gezielt beeinflussen lässt. Hierfür wurden zunächst einzelne Segmente aus einem Sägeblatt herausgetrennt und Einzahnproben mit variierenden Schneidenmikrogeometrien mittels Bürstspanen präpariert. Anschließend wurde das Einsatz- und Verschleißverhalten der zuvor hergestellten Proben in einem Kreissäge-Modellversuch untersucht.   This article describes how the service life of circular saw blades can be specifically influenced by cutting edge preparation. For this purpose, individual segments were first cut out of a saw blade. These single-tooth specimens with varying cutting edge microgeometries were prepared by abrasive brushing. Then the usage and wear behavior of the previously produced samples was investigated in a circular saw model test.

scholarly journals Experimental Study on Tool Wear and Delamination in Milling CFRPs with TiAlN- and TiN-Coated Tools

Coatings ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 623 ◽  
Author(s):  
Dervis Ozkan ◽  
Peter Panjan ◽  
Mustafa Sabri Gok ◽  
Abdullah Cahit Karaoglanli
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Failure Mechanisms ◽  
Cutting Tools ◽  
Machining Process ◽  
Dynamic Loads ◽  
Fiber Reinforced Polymers ◽  
Machining Parameters ◽  
Coated Tool ◽  
Cfrp Composite

Carbon fiber-reinforced polymers (CFRPs) have very good mechanical properties, such as extremely high tensile strength/weight ratios, tensile modulus/weight ratios, and high strengths. CFRP composites need to be machined with a suitable cutting tool; otherwise, the machining quality may be reduced, and failures often occur. However, as a result of the high hardness and low thermal conductivity of CFRPs, the cutting tools used in the milling process of these materials complete their lifetime in a short cycle, due to especially abrasive wear and related failure mechanisms. As a result of tool wear, some problems, such as delamination, fiber breakage, uncut fiber and thermal damage, emerge in CFRP composite under working conditions. As one of the main failure mechanisms emerging in the milling of CFRPs, delamination is primarily affected by the cutting tool material and geometry, machining parameters, and the dynamic loads arising during the machining process. Dynamic loads can lead to the breakage and/or wear of cutting tools in the milling of difficult-to-machine CFRPs. The present research was carried out to understand the influence of different machining parameters on tool abrasion, and the work piece damage mechanisms during CFRP milling are experimentally investigated. For this purpose, cutting tests were carried out using a (Physical Vapor Deposition) PVD-coated single layer TiAlN and TiN carbide tool, and the abrasion behavior of the coated tool was investigated under dry machining. To understand the wear process, scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) was used. As a result of the experiments, it was determined that the hard and abrasive structure of the carbon fibers caused flank wear on TiAlN- and TiN-coated cutting tools. The best machining parameters in terms of the delamination damage of the CFRP composite were obtained at high cutting speeds and low feed rates. It was found that the higher wear values were observed at the TiAlN-coated tool, at the feed rate of 0.05 mm/tooth.

High-quality cutting edge preparation of micromilling tools using wet abrasive jet machining process

2017 ◽  
Vol 12 (1) ◽  
pp. 45-51 ◽  
Author(s):  
E. Krebs ◽  
M. Wolf ◽  
D. Biermann ◽  
W. Tillmann ◽  
D. Stangier
Keyword(s):  
Cutting Edge ◽  
Machining Process ◽  
High Quality ◽  
Abrasive Jet Machining ◽  
Cutting Edge Preparation ◽  
Edge Preparation

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

2010 ◽  
Vol 33 ◽  
pp. 173-176
Author(s):  
X.Y. Wang ◽  
S.Q. Pang ◽  
Q.X. Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Experimental Research ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Life Testing ◽  
Processing Efficiency ◽  
Comparative Tests ◽  
Coated Carbide ◽  
Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

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