Predictive Models for Flank Wear on Coated Inserts

1999 ◽  
Vol 122 (1) ◽  
pp. 340-347 ◽  
Author(s):  
Patrick Kwon
Keyword(s):  
Wear Rate ◽  
Predictive Models ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Carbon Steels ◽  
Temperature History ◽  
Interface Temperature ◽  
Second Phase ◽  
Wear Rates ◽  
Hot Rolled

The purpose of this paper is to develop predictive models for flank wear that explicitly incorporate cutting temperature and the physical properties of coatings and work materials. The development of such models can minimize time-consuming machining experiments in predicting tool life by establishing flank wear models that can be applied to wide classes of coated inserts and work materials. To develop such models, a set of experiments was performed to understand the effect on flank wear due to the morphology and amount of the second phase in work materials. The plain carbon steels of AISI designation 1018, 1045, 1065, 1070, and 1095 in hot-rolled (pearlitic) and/or spherodized conditions were turned. The inserts with a single coating of TiN, TiCN, or Al2O3 were used in the cutting experiments. The temperature history at a remote location on the rake face was measured during cutting by using an infrared pyrometer with a fiber optic attachment. This temperature information was used to estimate the steady-state tool-chip interface temperatures using the inverse estimation scheme by Yen and Wright, 1986, ASME J. Eng. Ind., 108, pp. 252–263. The results were then used to predict the work-tool interface temperature using the scheme suggested by Oxley, 1989, The Mechanics of Machining: An Analytical Approach to Assessing Machinability, Wiley, New York, NY, p. 168. The results of this experiment showed that, for the spherodized steels, flank wear per sliding distance (the flank wear rate) increased with the cementite content. For the hot-rolled (pearlitic) steels, no conclusive evidence was found that correlates the flank wear rate with the cementite content. However, for pearlitic steels the wear rates, in general, were shown to increase with the flank temperature while for spherodized steels the rates decrease with the flank temperature. The reason for these trends can be explained by the microstructural difference between pearlitic and spherodized steels; therefore, the semi-empirical models of two-body and three-body wear developed by Rabinowicz (1967) and Rabinowicz et al. (1972) can be applied to describe the flank wear process. [S0742-4787(00)04501-X]

A Cobalt Diffusion Based Model for Predicting Crater Wear of Carbide Tools in Machining Titanium Alloys

2005 ◽  
Vol 127 (1) ◽  
pp. 136-144 ◽  
Author(s):  
Jiang Hua ◽  
Rajiv Shivpuri
Keyword(s):  
Wear Rate ◽  
Titanium Alloys ◽  
High Speed ◽  
Cutting Tools ◽  
Interface Temperature ◽  
Wear Model ◽  
Crater Wear ◽  
Wear Rates ◽  
Process Comparison ◽  
Thermally Driven

In machining titanium alloys with cemented carbide cutting tools, crater wear is the predominant wear mechanism influencing tool life and productivity. An analytical wear model that relates crater wear rate to thermally driven cobalt diffusion from cutting tool into the titanium chip is proposed in this paper. This cobalt diffusion is a function of cobalt mole fraction, diffusion coeficient, interface temperature and chip velocity. The wear analysis includes theoretical modeling of the transport-diffusion process, and obtaining tool–chip interface conditions by a nonisothermal visco-plastic finite element method (FEM) model of the cutting process. Comparison of predicted crater wear rate with experimental results from published literature and from high speed turning with WC/Co inserts shows good agreement for different cutting speeds and feed rate. It is seen that wear rates are independent of cutting time.

Phase Transformation and Its Effect on Flank Wear in Machining Steels

2002 ◽  
Vol 124 (3) ◽  
pp. 659-666 ◽  
Author(s):  
Wonsik Kim ◽  
Patrick Kwon
Keyword(s):  
Electron Microscopy ◽  
Phase Transformation ◽  
Flank Wear ◽  
Wear Behavior ◽  
Carbon Steels ◽  
Phase Identification ◽  
Material Interface ◽  
Austenitic Phase ◽  
Wear Rates ◽  
Flank Surface

In machining, the main wear mechanism on the flank surface of a tool is commonly believed to be abrasive wear [1,9]. Accordingly, work materials with a higher concentration of hard inclusions are expected to develop higher flank wear rates. However, the previous turning experiment [9] with plain carbon steels containing varying amounts of cementite inclusions did not exhibit the expected flank wear behavior. Other imperative phenomenon must be occurring at the tool-work material interface during machining, which diminishes the abrasive action of the cementite inclusions. To investigate this behavior, a series of turning tests with AISI 1045, 1070, and 4340 steels have been conducted; and the newly generated surface layers are examined for phase identification using Scanning Electron Microscopy (SEM), X-ray diffraction (XRD), and Transmission Electron Microscopy (TEM). At high cutting speeds (>200 m/min), flank wear is diminished as the cementite phase at the newly formed surface dissociates and diffuses into the matrix of the austenitic phase. Because the heated austenite phase is cooled extremely rapidly, martensitic and in some case even retained austenitic phases are formed. This is the evidence of phase transformation, which explains the flank wear data observed in [9]. In addition, phase transformation explains the scatter in flank wear data in the literature because the onset of phase transformation depends on the exact composition of the work materials as well as interfacial conditions such as temperature and pressure. This paper reports the experimental evidence of phase transformation and its consequence on flank wear in machining annealed steels.

Observations on the structure at the transformation interface of pearlite in steel

1990 ◽  
Vol 48 (4) ◽  
pp. 200-201
Author(s):  
F. A. Khalid ◽  
D. V. Edmonds
Keyword(s):  
Room Temperature ◽  
Thin Foil ◽  
Carbon Steels ◽  
Model Alloy ◽  
Growth Interface ◽  
Medium Carbon ◽  
Solution Treated ◽  
Medium Carbon Steels ◽  
Alloy Carbide ◽  
Hot Rolled

The austenite/pearlite growth interface in a model alloy steel (Fe-1 lMn-0.8C nominal wt%) is being investigated. In this particular alloy pearlite nodules can be grown isothermally in austenite that remains stable at room temperature, thus facilitating examination of the transformation interfaces. This study presents preliminary results of thin foil TEM of the austenite/pearlite interface, as part of a programme of aimed at studying alloy carbide precipitation reactions at this interface which can result in significant strengthening of microalloyed low- and medium- carbon steels L Similar studies of interface structure, made on a partially decomposed high- Mn austenitic alloy, have been reported recently.The experimental alloys were made as 50 g argon arc melts using high purity materials and homogenised. Samples were hot- rolled, swaged and machined to 3mm diameter rod, solution treated at 1300 °C for 1 hr and WQ. Specimens were then solutionised between 1250 °C and 1000 °C and isothermally transformed between 610 °C and 550 °C for 10-18 hr and WQ.

SAE 1039

Alloy Digest ◽  
1977 ◽  
Vol 26 (2) ◽  
Keyword(s):  
Fracture Toughness ◽  
Low Cost ◽  
Manganese Content ◽  
Heat Treating ◽  
General Purpose ◽  
Carbon Steels ◽  
The Other ◽  
Steel Mills ◽  
Medium Strength ◽  
Hot Rolled

Abstract SAF 1039 steel can be used in the hot-rolled, normalized, oil-quenched-and-tempered or water-quenched-and-tempered condition for general-purpose construction and engineering. Its manganese content is a little higher than some of the other standard carbon steels with comparable carbon levels; this gives it slightly higher hardenability and hardness. It provides medium strength and toughness at low cost. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as forming, heat treating, machining, joining, and surface treatment. Filing Code: CS-66. Producer or source: Carbon steel mills.

Strategies of maintenance and repair of agricultural machinery

2020 ◽  
pp. 38-48
Author(s):  
Aleksey S. Dorokhov ◽  
Aleksandr V. Denisov ◽  
Aleksey A. Solomashkin ◽  
Valeriy S. Gerasimov
Keyword(s):  
Wear Rate ◽  
Technical Condition ◽  
Research Purpose ◽  
Agricultural Machinery ◽  
Maintenance And Repair ◽  
Wear Rates ◽  
Urgent Task ◽  
Machine Parts ◽  
Current Value ◽  
Agricultural Machines

Modern machines are subject to progressive wear that occurs at different rates, which leads to unpredictable failures that reduce the reliability and durability of machines. The strategy of maintenance and repair is aimed at eliminating these problems. (Research purpose) The research purpose is in analyzing the basic principles of the strategy of maintenance and repair of agricultural machinery in order to ensure control of the technical condition of machine parts. (Materials and methods) When resource diagnostics is used, , the allowable value of the parameter is set in advance for a part . This value is the tolerance that corresponds to a certain wear rate of the part. The tolerance is set based on the condition that if the current value of the controlled resource parameter during the next diagnosis is less than the set value, then such a part at the current value of the wear rate can be finalized until the next inter-control check. Taking into account the wear rate of the same type of parts from the group when determining the allowable wear during their resource diagnostics becomes an urgent task. (Results and discussions) As a result of research, the article presents "Methodology for determining the main indicators of reliability of parts of agricultural machines with different wear rates" and "Methodology for determining the tolerance system of parts of agricultural machines with different wear rates". (Conclusions) The article presents the tolerance system that reduces the probability of failure of machine parts in operation. During resource diagnostics, those parts whose resource parameters exceed the tolerance are rejected.

scholarly journals Sliding Wear of Conventional and Suspension Sprayed Nanocomposite WC-Co Coatings: An Invited Review

2021 ◽  
Author(s):  
R. Ahmed ◽  
O. Ali ◽  
C. C. Berndt ◽  
A. Fardan
Keyword(s):  
Wear Rate ◽  
Thermal Spray ◽  
Sliding Wear ◽  
Failure Modes ◽  
Thermal Spray Coatings ◽  
Annual Growth Rate ◽  
Total Energy Consumption ◽  
Wear Performance ◽  
Wear Rates ◽  
Spray Coatings

AbstractThe global thermal spray coatings market was valued at USD 10.1 billion in 2019 and is expected to grow at a compound annual growth rate of 3.9% from 2020 to 2027. Carbide coatings form an essential segment of this market and provide cost-effective and environmental friendly tribological solutions for applications in aerospace, industrial gas turbine, automotive, printing, oil and gas, steel, and pulp and paper industries. Almost 23% of the world’s total energy consumption originates from tribological contacts. Thermal spray WC-Co coatings provide excellent wear resistance for industrial applications in sliding and rolling contacts. Some of these applications in abrasive, sliding and erosive conditions include sink rolls in zinc pots, conveyor screws, pump housings, impeller shafts, aircraft flap tracks, cam followers and expansion joints. These coatings are considered as a replacement of the hazardous chrome plating for tribological applications. The microstructure of thermal spray coatings is however complex, and the wear mechanisms and wear rates vary significantly when compared to cemented WC-Co carbides or vapour deposition WC coatings. This paper provides an expert review of the tribological considerations that dictate the sliding wear performance of thermal spray WC-Co coatings. Structure–property relationships and failure modes are discussed to grasp the design aspects of WC-Co coatings for tribological applications. Recent developments of suspension sprayed nanocomposite coatings are compared with conventional coatings in terms of performance and failure mechanisms. The dependency of coating microstructure, binder material, carbide size, fracture toughness, post-treatment and hardness on sliding wear performance and test methodology is discussed. Semiempirical mathematical models of wear rate related to the influence of tribological test conditions and coating characteristics are analysed for sliding contacts. Finally, advances for numerical modelling of sliding wear rate are discussed.

Experimental investigation of a slip-line field model for a worn cutting tool

2013 ◽  
Vol 228 (8) ◽  
pp. 1398-1404 ◽  
Author(s):  
Alper Uysal ◽  
Erhan Altan
Keyword(s):  
Wear Rate ◽  
Slip Line ◽  
Field Model ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Rake Angle ◽  
Uncut Chip Thickness ◽  
Line Field

In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

Determination of Steady-State Adhesive Wear Rate

2005 ◽  
Author(s):  
L. J. Yang
Keyword(s):  
Steady State ◽  
Wear Rate ◽  
Wear Test ◽  
Standard Test ◽  
Test Method ◽  
Testing Time ◽  
Wear Coefficient ◽  
Wear Rates ◽  
Test Methodology

Wear rates obtained from different investigators could vary significantly due to lack of a standard test method. A test methodology is therefore proposed in this paper to enable the steady-state wear rate to be determined more accurately, consistently, and efficiently. The wear test will be divided into four stages: (i) to conduct the transient wear test; (ii) to predict the steady-state wear coefficient with the required sliding distance based on the transient wear data by using Yang’s second wear coefficient equation; (iii) to conduct confirmation runs to obtain the measured steady-state wear coefficient value; and (iv) to convert the steady-state wear coefficient value into a steady-state wear rate. The proposed methodology is supported by wear data obtained previously on aluminium based matrix composite materials. It is capable of giving more accurate steady-state wear coefficient and wear rate values, as well as saving a lot of testing time and labour, by reducing the number of trial runs required to achieve the steady-state wear condition.

Relevance of ROT control for hot rolled low carbon steels

2001 ◽  
Vol 72 (5-6) ◽  
pp. 221-224 ◽  
Author(s):  
Madakasira Phaniraj ◽  
Shama Shamasundar ◽  
Ashok Kumar Lahiri
Keyword(s):  
Carbon Steels ◽  
Low Carbon ◽  
Low Carbon Steels ◽  
Hot Rolled

scholarly journals Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

2020 ◽  
Vol 5 (2) ◽  
pp. 50-54
Author(s):  
Muataz Al Hazza ◽  
Khadijah Muhammad
Keyword(s):  
Statistical Analysis ◽  
Wear Rate ◽  
Taguchi Method ◽  
Feed Rate ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis.  JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

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