Effect of Cutting Speed on Chipping and Wear of the SiAlON Ceramic Tool in Dry Finish Turning of the Precipitation Hardenable IN100 Aerospace Superalloy

2018 ◽  
Vol 141 (2) ◽  
Author(s):  
Mohamed A. Shalaby ◽  
Stephen C. Veldhuis
Keyword(s):  
Photoelectron Spectroscopy ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Ceramic Tool ◽  
Finish Turning ◽  
Ceramic Tools ◽  
Sialon Ceramic ◽  
Tool Edge ◽  
Chip Compression Ratio

Inconel 100 (IN100) aerospace superalloy is used in manufacturing aero-engine components that operate at intermediate temperatures. It is considered to be a hard-to-cut material. Chipping of the tool edge is one of the major failure mechanisms of ceramic tools in finish cutting of superalloys, which causes a sudden breakage of the cutting edge during machining. Cutting temperature significantly depends on cutting speed. Varying the cutting speed will affect the frictional action during the machining operations. However, proper selection of the cutting variables, especially the cutting speed, can prevent chipping occurrence. In this work, the influence of controlling the cutting speed on the chipping formation in dry finish turning of IN100 aerospace superalloy using SiAlON ceramic tool has been investigated. Scanning electron microscope (SEM)/energy dispersing spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), and three-dimensional wear measurements were used to make the investigations of the worn tool edges. It was found that variations of the cutting speeds in a certain range resulted in the generation of different lubricious and protective tribo-films. The presence of these tribo-films at the cutting region proved essential to prevent chipping of the cutting tool edge and to improve its wear resistance during finish turning of age-hardened IN 100 using SiAlON ceramic tools. Chip compression ratio and calculated values of the coefficient of friction at the tool–chip interface confirmed these results.

scholarly journals Influence of CaF2@Al2O3 on Cutting Performance and Wear Mechanism of Al2O3/Ti(C,N)/CaF2@Al2O3 Self-Lubricating Ceramic Tools in Turning

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2922
Author(s):  
Shuai Zhang ◽  
Guangchun Xiao ◽  
Zhaoqiang Chen ◽  
Chonghai Xu ◽  
Mingdong Yi ◽  
...  
Keyword(s):  
Adverse Effect ◽  
Solid Lubricant ◽  
Cutting Temperature ◽  
The Self ◽  
Cutting Performance ◽  
Ceramic Tool ◽  
Ceramic Tools ◽  
Al2o3 Particles ◽  
Better Than

This study aimed at improving the cutting performance of a ceramic tool to which were added solid lubricant particles. We prepared the self-lubricating ceramic tool by adding CaF2@Al2O3 instead of CaF2, and the self-lubricating ceramic tool with Al2O3 as matrix phase, Ti(C,N) as reinforcement phase. The properties of the ceramic tool with different contents of CaF2@Al2O3 and CaF2 were studied by turning 40Cr. Compared with the ceramic tool with 10 vol.% CaF2, the main cutting force and the cutting temperature of the ceramic tool with 10 vol.% CaF2@Al2O3 decreased by 67.25% and 38.14% respectively. The wear resistance and machining surface quality of the ceramic tool with CaF2@Al2O3 were better than the ceramic tool to which were directly added CaF2. The optimal content of CaF2@Al2O3 particles was determined to be 10 vol.%. The addition of CaF2@Al2O3 particles effectively reduces the adverse effect of direct addition of CaF2 particles on the ceramic tool, and plays a role in improving the cutting performance of the ceramic tool.

Cutting Behavior of Self-Lubricating Ceramic Tool in Dry Machining of 40Cr Quenched Steel

2021 ◽  
Vol 871 ◽  
pp. 176-188
Author(s):  
Ben Yuan Wang ◽  
Guang Chun Xiao ◽  
Zhao Qiang Chen ◽  
Ming Dong Yi ◽  
Jing Jie Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Solid Lubricant ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Ceramic Composites ◽  
Ceramic Tool ◽  
Cutting Depth ◽  
Ceramic Tools

In this paper, the dry cutting performance of Al2O3/TiC-based ceramic composites with nanoCaF2 was studied. Compared with the Al2O3/TiC ceramic tool, the Al2O3/TiC/CaF2 ceramic tool has lower cutting force, cutting temperature and surface roughness when milling 40Cr hardened steel. Three cutting parameters of cutting speed, feed per tooth, and cutting depth were used to conduct orthogonal experiments to study its changing trend. Through testing of cutting force, cutting temperature and surface roughness, and by comparison with ceramic tools without nanosolid lubricant added, the order of influence of three cutting parameters on cutting force, cutting temperature and surface roughness was obtained. The experimental results showed that the cutting force, cutting temperature and surface roughness of Al2O3/TiC/CaF2 ceramic tools containing nanoCaF2 werebetter than those of Al2O3/TiC ceramic tools. The cutting force, the cutting temperature, and the surface roughness were respectively reduced by 16.5%, 25.8% and 43% compared to when no solid lubricant was added. In addition, after adding solid lubricant, the effect of cutting depth on cutting force was significantly reduced. The average friction coefficient of the tool rake surface was 31.1% lower than that of ceramic tools without solid lubricant. In order to explain this phenomenon, through scanning electron microscopy (SEM) scanning and energy spectroscopy (EDS) elemental analysis, the wear reduction mechanism of solid lubricants was analyzed, that is, during the cutting process, nanosolid lubricants precipitated and formed lubricating film on the rake surface of the tool to reduce the friction coefficient. This was also the main reason for reducing the cutting temperature.

Machinability Investigation in High Speed Turning of Powder Metallurgy Nickel-Based Superalloy with Sialon Ceramic Inserts

2010 ◽  
Vol 139-141 ◽  
pp. 805-808 ◽  
Author(s):  
Yang Qiao ◽  
Xing Ai ◽  
Zhan Qiang Liu ◽  
Jun Zhao
Keyword(s):  
Powder Metallurgy ◽  
Thermal Shock ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Temperature Strength ◽  
Sialon Ceramic ◽  
Nickel Based Superalloy

An experimental investigation was carried out to understand the behavior of a powder metallurgy nickel-based superalloy when machined with sialon ceramic insert tools. Turning experiments were carried out at different cutting speeds and feed rates while depth of cut was kept constant. Cutting tool performance was evaluated with respect to temperature and cutting forces generated during turning, and tool wear. The sialon ceramic cutting tool showed high performance when increasing cutting speed, the machining experiments showed that sialon ceramic tools performed better at cutting speed up to 80 m/min. Abrasion and adhesion was the dominant wear mechanisms. Chipping on the tool rake and flank faces, as well as catastrophic failure under thermal shock and mechanical loading, was also observed in experiments. As cutting temperature was very high when turning powder metallurgy nickel-based superalloy, good high-temperature strength and thermal shock resistance were indispensable to the cutting tools for machinging this kind of material.

scholarly journals Experimental Evaluation in Dry Machining of Inconel 718 Using Coated Carbides

2020 ◽  
pp. 1-11
Author(s):  
M. M. Reddy ◽  
N. S. Reddy ◽  
J. N. Evan
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
High Hardness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Work Piece ◽  
Ceramic Tools ◽  
Optimal Cutting Parameters

Past two decades, the usage of ceramic tools has increased especially in milling and turning process. These advanced ceramic tools have good characteristics that are capable in maintaining high hardness in temperatures and also wears much slower when compared to carbide tools. With limited data available on the tool itself, research is to be done on these advance ceramic tools. The main purpose of this research project is to determine the cutting parameters affecting the cutting temperature and cutting force. The cutting parameters are cutting speed, depth of cut and feed rate. Silicon Nitride is chosen as the tool and Steel AISI4140 is chosen as the work piece. Analysis is conducted through Box-Behnken method with 3 levels, 3 factors and 2 responses. The regression model for cutting temperature and cutting force responses are identified. Analysis of Variance (ANOVA) is done to determine the effect of the cutting parameters and their contribution towards the cutting temperature and cutting force response. It is found that feed rate has the most influence on cutting temperature and force. The optimal cutting parameters that produce the lowest cutting temperature and lowest cutting force are also obtained.

scholarly journals Infrared Thermography for Investigation of Surface Quality in Dry Finish Turning of Ti6Al4V

Metals ◽  
2022 ◽  
Vol 12 (1) ◽  
pp. 154
Author(s):  
Manuela De Maddis ◽  
Vincenzo Lunetto ◽  
Valentino Razza ◽  
Pasquale Russo Spena
Keyword(s):  
Surface Roughness ◽  
Infrared Thermography ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Finish Turning ◽  
Machined Parts ◽  
Cutting Operation ◽  
Selection Of

The machining of titanium alloys always raises issues because of their peculiar chemical and physical characteristics as compared to traditional steel or aluminum alloys. A proper selection of parameters and their monitoring during the cutting operation makes it possible to minimize the surface roughness and cutting force. In this experimental study, infrared thermography was used as a control parameter of the surface roughness of Ti6A4V in dry finish turning. An analysis of variance was carried out to determine the effect of the main cutting parameters (cutting speed and feed rate) on the surface roughness and cutting temperature. In the examined range of the machining parameters, cutting speed and feed were found to have a primary effect on the surface roughness of the machined parts. Cutting speed also significantly affected the temperature of the cutting region, while feed was of second order. Higher cutting speeds and intermediate feed values gave the best surface roughness. A regression analysis defined some models to relate the cutting temperature and surface roughness to the machining parameters. Infrared thermography demonstrated that the cutting temperature could be related to roughness.

Effect of High-Temperature Alloy Cutting Speed on Tool Wear

2014 ◽  
Vol 800-801 ◽  
pp. 124-128
Author(s):  
Yu Wang ◽  
Yi Wen Wang ◽  
Zhong Yang Zhao ◽  
Ye Cai
Keyword(s):  
High Temperature ◽  
Tool Wear ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
High Temperature Alloy ◽  
Software Applications ◽  
3D Software ◽  
Cutting Model

High-temperature alloy is an important material in making critical aerospace engine parts, it is also used in weapons industry, energy, chemical, power, etc. In this article, DEFORM-3D software applications to establish a three-dimensional cutting model of high-temperature alloy GH4169. Combined with cutting experiment analysis the characteristics of the tool wear and cutting temperature by change cutting speeds, and optimized cutting parameters combined with experimental on tool wear.

scholarly journals Preparation of Al2O3/Ti(C,N)/ZrO2/CaF2@Al(OH)3 Ceramic Tools and Cutting Performance in Turning

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3820
Author(s):  
Chen ◽  
Zhang ◽  
Guo ◽  
Ji ◽  
Guo ◽  
...  
Keyword(s):  
Wear Mechanisms ◽  
Mechanical Performance ◽  
Flank Wear ◽  
Adhesive Wear ◽  
Cutting Speed ◽  
Hot Press ◽  
Ceramic Tool ◽  
Ceramic Tools ◽  
Lubricating Film ◽  
Hot Press Sintering

Aiming at the contradiction between the lubricating performance and mechanical performance of self-lubricating ceramic tools. CaF2@Al(OH)3 particles were prepared by the heterogeneous nucleation method. An Al2O3/Ti(C,N) ceramic tool with CaF2@Al2(OH)3 particles and ZrO2 whiskers was prepared by hot press sintering (frittage). The cutting performances and wear mechanisms of this ceramic tool were investigated. Compared with the Al2O3/Ti(C,N) ceramic tool, the Al2O3/Ti(C,N)/ZrO2/CaF2@Al(OH)3 ceramic tool had lower cutting temperatures and surface roughness. When the cutting speed was increased from 100m/min to 300m/min, a lot of CaF2 was smeared onto the surface of the ceramic tool, and the flank wear of the Al2O3/Ti(C,N)/ZrO2/CaF2@Al(OH)3 ceramic tool was reduced. The main wear mechanisms of the Al2O3/Ti(C,N)/ZrO2/CaF2@Al(OH)3 ceramic tool were adhesive wear and micro-chipping. The formation of solid lubricating film and the improvement of fracture toughness by adding ZrO2 whiskers and CaF2@Al(OH)3 were important factors for the Al2O3/Ti(C,N)/ZrO2/CaF2@Al(OH)3 ceramic tool to have better cutting performances.

Study of a Novel Ceramic Tool Performance in the Machining of Ti-6Al-7Nb Alloys

MRS Advances ◽  
2019 ◽  
Vol 4 (55-56) ◽  
pp. 3007-3015
Author(s):  
Ricardo del Risco-Alfonso ◽  
Hector R. Siller ◽  
Roberto Pérez-Rodríguez ◽  
Arturo Molina
Keyword(s):  
Titanium Alloys ◽  
High Performance ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Point Of View ◽  
High Plasticity ◽  
Ceramic Tool ◽  
Ceramic Tools ◽  
Ceramic Cutting Tool ◽  
Tool Performance

ABSTRACTConsidering their distinctive properties, titanium alloys are used in foremost industries, including the aeronautic, automotive and biomedical industries. The reduced machinability of titanium alloys is due to their low thermal conductivity and high plasticity behavior. In the biomedical sector, one of the most studied alloys is Ti-6Al-4V. In the case of the Ti-6Al-7Nb alloy, scarce investigations are identified, related to machinability studies. The machining of Ti-6Al-7Nb alloy requires the development of new tools with higher properties, which provide better performance. The objective of this study is to present the experimental results related to a novel ceramic cutting tool, in terms of cutting tool life and productivity, in the machining of Ti-6Al-7Nb alloy. A turning operation of a 25 mm diameter bar was performed; the cutting speed was varied in three levels. The results showed the high performance of this type of tools, from the point of view of machinability. The values of the obtained cutting forces are found in the ranges reported by the consulted literature using ceramic tools. The surface roughness values were considered appropriate, taking into account that the tool is recommended for roughing and semi-finishing operations. The most relevant results were obtained in terms of productivity, considering that the performance is 2.53 times higher than the presented in similar works.

Experimental Research on Orthogonal Cutting and Oblique Cutting of Hardened Steel GCr15

2008 ◽  
Vol 375-376 ◽  
pp. 192-196 ◽  
Author(s):  
Yu Wang ◽  
Peng Wang ◽  
Hong Min Pen ◽  
Yu Fu Li ◽  
Xian Li Liu
Keyword(s):  
Inclination Angle ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Shear Zones ◽  
Feed Speed ◽  
Oblique Cutting ◽  
Strain And Strain Rate

Experiment of hard cutting GCr15 with PCBN cutting tools, the influence of tool’s inclination angle and cutting parameters (cutting speed and feed speed) on cutting forces and cutting temperature are studied. A three-dimensional finite elements model using the commercial software Deform 3D 5.03 is developed. The friction between the tool and the chip is assumed to follow a modified Coulomb friction law and the adaptive remeshing technique is using for the formation of chip. The workpiece material property is a function of temperature, strain, and strain rate in the primary and secondary shear zones. Finite element method is used to simulate three-dimensional precision cutting, including orthogonal cutting and oblique cutting. The cutting forces and back forces are slightly changed by tool’s inclination angle. However, in high cutting speed, the cutting force decrease as the tool’s inclination angle increase, while the cutting temperature increase as the tool’s inclination angle increase. The simulation results are compared with experimentally measured data and found to be in good agreement to some extent.

Sign in / Sign up

Export Citation Format

Share Document