Chip Adhesion and Tool Wear in Driven Rotary Cutting of Stainless Steel

2017 ◽  
Author(s):  
Hiroyuki Sasahara ◽  
Masato Goto ◽  
Wataru Takahashi ◽  
Hiromasa Yamamoto ◽  
Toshiyuki Muraki
Keyword(s):  
Stainless Steel ◽  
Velocity Ratio ◽  
Tangential Component ◽  
Circumferential Velocity ◽  
Thermal Cracks ◽  
Tool Edge ◽  
Rotary Cutting ◽  
Chip Adhesion ◽  
Performance Results ◽  
Tool Rotation

In driven rotary cutting of stainless steel, adhesions sometimes occur on the tool, causing increased wear. The type of coolant supplying methods and tool rotation speed affects largely on the adhesion because it depends on the temperature and lubricating performance. Results showed that in a circumferential velocity ratio of 1.0, which means tangential component of tool peripheral speed is equal to work surface speed, there is no adhesion on the tool after cutting. In a circumferential velocity ratio of 2.0, adhesion occurred with overcooling of the flood coolant, and wear increased by adhesions to the rotating tool. It was found that the thermal cracks on the cutting edge was one of the factors of increased wear and chipping. Adhesives on the tool edge also accelerated the chipping.

Effect of Cutting Conditions on Tool Wear in Driven Rotary Cutting of Maraging Steel

2015 ◽  
Vol 656-657 ◽  
pp. 208-213
Author(s):  
Masato Goto ◽  
Wataru Takahashi ◽  
Wataru Sasaki ◽  
Takeshi Toujyo ◽  
Yuji Takagi ◽  
...  
Keyword(s):  
Tool Wear ◽  
Maraging Steel ◽  
Tool Life ◽  
Velocity Ratio ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Circumferential Velocity ◽  
Optimal Conditions ◽  
Rotary Cutting ◽  
Tool Rotation

In this paper, driven rotary cutting of maraging steel was carried out and the influence on tool wear of difference cutting conditions was investigated. As cutting conditions, different coolant conditions, cutting speeds, circumferential velocity ratios, tool inclination angles, tool rotation directions and normal rake angles were tested. We found that as the coolant quantity decreased and cutting speed increased, the width of flank wear increased. It was also found that the circumferential velocity ratio, tool inclination angle, tool rotation direction and normal rake angle have optimal conditions that decrease wear. Optimal conditions were chosen, and a tool life test was carried out. As a result, driven rotary cutting was achieved with 11 or more times the tool life of conventional turning.

1020 Tool Edge Temperature in Tapping of Stainless Steel

2012 ◽  
Vol 2012.49 (0) ◽  
pp. 102001-102002
Author(s):  
Koji SHIMANUKI ◽  
Ryutaro TANAKA ◽  
Syuhei YAMAZAKI ◽  
Akira HOSOKAWA ◽  
Takashi UEDA ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Tool Edge ◽  
Edge Temperature

Improvements in Lightly Loaded Rotor/Bearing and Rotor/Seal Models

1988 ◽  
Vol 110 (2) ◽  
pp. 129-136 ◽  
Author(s):  
A. Muszynska
Keyword(s):  
Stability Analysis ◽  
Fluid Dynamic ◽  
Velocity Ratio ◽  
Nonlinear Function ◽  
Circumferential Velocity ◽  
Rotating Shaft ◽  
Model Adequacy ◽  
Dynamic Forces ◽  
Key Factor ◽  
Lateral Mode

A model for lightly loaded steadily rotating shaft/bearing/seal systems is proposed in this paper. The model is based on modal characteristics for the rotor, and rotational characteristics for the fluid dynamic forces generated in bearings and/or seals. The fluid average circumferential velocity ratio as a nonlinear function of shaft eccentricity represents a key factor in the model. The model is extremely useful for rotor stability analysis. The model adequacy was proved for one and two lateral mode models of rotors.

Optimization of Friction Crush Welding of Two Dissimilar Metals: Aluminium 6061 T-6 and Stainless Steel AISI 304

2020 ◽  
Author(s):  
Prem Singh ◽  
Dharmpal Deepak ◽  
Gurinder Singh Brar
Keyword(s):  
Stainless Steel ◽  
Bond Strength ◽  
Feed Rate ◽  
Specific Weight ◽  
Vehicle Body ◽  
Dissimilar Metals ◽  
Aisi 304 ◽  
Steel Aisi ◽  
Tool Rotation ◽  
Stainless Steel Aisi

Abstract In order to cater increasing need of lightweight and strong structures to be used in various industries like ship manufacturing, railways transportation, vehicle body cell etc., efforts have been made to develop and assess various welding or joining techniques. Dissimilar metal welding offers promising solution in this direction due to modification of properties by combining two dissimilar metals in terms of mechanical properties and better corrosion or electrical properties with lesser specific weight. Stainless steel of grade AISI 304 is widely used for manufacturing application in different industries and aluminum alloy 6061 T-6 has gaining importance in welding due to its high corrosive resistance and high weldability properties. In the present work, welding of dissimilar metals i.e. Aluminium 6061 T-6 and Stainless Steel – AISI 304 was carried out with new welding technique i.e. Friction Crush Welding (FCW). Dissimilar welds prepared at different levels of tool rotation and feed rate were characterized in terms of bond strength. Taguchi L9 Design of Experiments (DOE) was used to find optimal process parameters for dissimilar FCW. The theoretical optimum bond strength calculated using Taguchi L9 was 5134.53 N at tool rotation of 740 rpm and feed rate of 45 mm/mim. The theoretical optimum value was in line with the experimental results.

Experimental Evaluation of Turbocharger Turbine Performance Under Pulsating Flow Conditions

2005 ◽  
Author(s):  
S. Szymko ◽  
R. F. Martinez-Botas ◽  
K. R. Pullen
Keyword(s):  
Strouhal Number ◽  
Energy Content ◽  
Velocity Ratio ◽  
Pulse Frequency ◽  
Pulsating Flow ◽  
A Value ◽  
Engine Speed Range ◽  
Action Model ◽  
Unsteady Effects ◽  
Performance Results

The steady and pulsating performance results of a turbocharger mixed-flow turbine are presented. The results are taken at an equivalent speed of 70% (42,000rpm) for a pulse frequency range of 20 to 80 Hz. All instantaneous parameters required for unsteady performance evaluation are measured and discussed. Significant improvements to the measurement of instantaneous actual power have been carried out. Large variations in the operating point of the turbine occur in each pulse cycle, a velocity ratio range of 0.43 to 1.28 is seen for a 20 Hz pulse, this range reduces as the pulse frequency increases and unsteady effects become more prominent. During periods of turbine freewheeling, negative efficiencies can arise due to momentum transfer from the turbine to the working gas, although detrimental to the efficiency the energy content in these regimes are low. The use of a modified Strouhal number (MSt.) and a pressure modified Strouhal number (PMSt.) has proved useful in assessing when the onset of unsteadiness of the flow will become significant, a value of 0.1 has been used as an appropriate limit to steadiness. The results suggest that for a typical engine speed range the rotor may be considered quasi-steady whilst the turbine stage is predominately operating in an unsteady regime. Inference from the experimental data would suggest it is adequate to capture the performance of a turbine under pulsating flow using a ‘quasi-steady’ model when the MSt. < 0.1, and a ‘filling and emptying’ code when a PMSt. < 0.1 and above this value a ‘wave action’ model is more appropriate.

Study on Applying Cavitation in Micro Drilling of Austenite Stainless Steel — Control of Burr in Through Hole Drilling —

2010 ◽  
Vol 4 (1) ◽  
pp. 15-20 ◽  
Author(s):  
Akira Mizobuchi ◽  
◽  
Hitoshi Ogawa ◽  
Keyword(s):  
Stainless Steel ◽  
Burr Formation ◽  
Hole Drilling ◽  
Drilling Tool ◽  
Burr Height ◽  
Austenite Stainless Steel ◽  
Micro Drilling ◽  
Chip Adhesion ◽  
Conventional Drilling ◽  
Through Hole

Microdrilling is required to produce nozzles for fiber, fuel etc. A problem arising in microdrilling is the need to remove chips to avoid tool breakage. This paper deals with how cavitation affects machining fluid using ultrasonic vibration for chip control. Thrust force, hole shape and burr formation are observed in drilling austenite stainless steel SUS304 with a through hole 0.1mm in diameter. Cavitation-assisted drilling reduces chip adhesion and burr height while drilling number increases, as compared to conventional drilling. During through-hole drilling, cavitation occurs in a blister generated by machining fluid at the hole exit. The burr height in cavitation-assisted drilling is smaller than that in conventional drilling. Tool life in through-hole drilling is the same as in blind-hole drilling. We studied the effect of cavitation on burr removal using B4C powder.

Influence of tool rotation errors on flank machined surface

2017 ◽  
Vol 232 (13) ◽  
pp. 2420-2429
Author(s):  
Yanlong Cao ◽  
Weixin Hu ◽  
Jiangxin Yang ◽  
Huichao Shang ◽  
Wenbo Wang ◽  
...  
Keyword(s):  
Cutting Tool ◽  
Geometric Error ◽  
Machining Process ◽  
Flank Milling ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Tool Runout ◽  
Tool Edge ◽  
Tool Rotation ◽  
Deformation Error

In flank milling, the machined metal surface is formed by the edge of the cutting tool and is thus affected by tool errors. Cutting tool rotation errors affect the movement of the tool teeth and thus change the trajectory of the tool edge. This change will also affect the cutting force, which will result in deformation in the cutting process. Previous studies focus mostly on the cutting tool runout error and ignore the effect of tool deformation. In this article, we built a mathematical model of the machining process that considers not only the tool runout error but also the tool tilt deformation error. Using this model, we analyzed how the tool rotation error will influence workpiece surface quality and surface frequency. Results show that feed rate and rotation errors will affect surface roughness, geometric error, and surface energy distribution.

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