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.

Study on Cutting Performance of the Alumina Based Nanocomposite Ceramic Tool

2014 ◽  
Vol 941-944 ◽  
pp. 1917-1921
Author(s):  
Qi Fen Zhou ◽  
Peng Zhou ◽  
Hai Ying Zhang
Keyword(s):  
Tool Wear ◽  
Failure Modes ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Crater Wear ◽  
Tool Failure ◽  
Ceramic Tools ◽  
Ceramic Cutting Tool ◽  
Adhesion Wear

In this paper, the oxide nanometer composite cutting performance of ceramic tools cutting cast iron were studied. And the tool failure modes were mainly analyzed. Through the study found that, with the increase of tool wear with cutting speed, failure forms mainly adhesion wear. When the cutting speed is low, the knife before the crater wear become the main form of ceramic cutting tool wear, boundary wear and the surface of the knife after wear is also very serious. And in the process of cutting, the collapse edge can also occur now; With the increase of cutting speed, collapse become the main failure forms of cutter blade.

TiB2 Ceramic Tool Turning 45# Steel Experimental Study

2012 ◽  
Vol 476-478 ◽  
pp. 1067-1070
Author(s):  
Xiao Bin Zhang ◽  
Xia Chang ◽  
Fu Hui Han ◽  
Wei Jiu Huang
Keyword(s):  
Electron Microscopy ◽  
Experimental Study ◽  
Friction And Wear ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Ceramic Tool ◽  
Ceramic Cutting Tool ◽  
Blade Tip ◽  
Flank Face ◽  
Scanning Electron

By using ordinary lathe, carried out cutting experimental study with cylindrical turning 45# steel on TiB2 ceramic cutting tool. By using Stereo Microscopy and Scanning Electron Microscopy, recorded cutting tool surface’s friction and wear conditions. The results showed that higher cutting speed could made surface roughness decrease and surface quality better; TiB2 ceramic cutting tool’s wear mechanism was abrasive wear, aoxidation wear; wear of blade tip and main flank face were more serious.

Cutting Force, Temperature and Wear Behavior in Dry Machining of Nodular Cast Iron with Si3N4/TiC Micro-Nano-Composite Ceramic Tool

2013 ◽  
Vol 711 ◽  
pp. 267-271 ◽  
Author(s):  
Zhi Jie Lü ◽  
Xian Chun Song ◽  
Ming Feng Ding ◽  
Yong Hui Zhou
Keyword(s):  
Cast Iron ◽  
Wear Rate ◽  
Cutting Tool ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Nodular Cast Iron ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Ceramic Tool ◽  
Ceramic Cutting Tool

In this paper, a type of Si3N4/TiC micro-nanocomposite ceramic tool materials were fabricated via hot pressing technique by adding Si3N4 and TiC nanoparticles. Cutting forces, temperature and wear behavior in dry machining of nodular cast iron with Si3N4/TiC micro-nanocomposite ceramic tool were investigated, in comparison with a commercial Sialon ceramic tool. Turning experiments were carried out at three different cutting speeds, which were 110, 175, and 220 m/min. Feed rate ( f ) and depth of cut (ap) were kept fixed at 0.1 mm/rev and 0.5 mm. The results show that the radial thrust force (Fy) become the largest among the three cutting force components (Fx , Fy and Fz), and Fy is the most sensitive to the changes of feed rate and depth of cut. In dry cutting of nodular cast iron, the cutting tool temperature rise rapidly with increase in cutting speed. The cutting temperature reach nearly 1000°C at the cutting speed of 220 m/min. The two types of ceramic tools have similar cutting performance, while the Si3N4/TiC micro-nanocomposite tool exhibits a better cutting performance than that of the Sialon tool. The wear rate of Si3N4/TiC micro-nanocomposite ceramic cutting tool is mainly dominated by the abrasion, while the wear rate of Sialon ceramic cutting tool is dominated by the abrasive action, and pullout of grains.

Research on the Cutting Property of Ceramic Tool Cutting Nickel Based Superalloy GH4169

2014 ◽  
Vol 800-801 ◽  
pp. 87-91
Author(s):  
Yu Bo Liu ◽  
Yong De Zhang ◽  
Can Zhao
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Ceramic Tool ◽  
Ceramic Cutting Tool ◽  
Nickel Based Superalloy ◽  
Tool Wear Mechanism ◽  
Tool Cutting ◽  
Notch Wear

This paper will use the Al2O3-SiCw whisker toughening ceramic tool WG300 and Si3N4-Al2O3 (Sialon) SX9 ceramic tool cutting performance test.Study on different cutting speed, ceramic cutting tool in machining nickel based high-temperature alloy tool life and tool wear mechanism, and analysis of the wear form under different cutting parameters. The test results show that: with the increase of the cutting speed, WG300 and SX9 two kinds of tool durability showed a downward trend, the value of VB is higher than that of Al2O3-SiCw whisker reinforced ceramic cutting tool flank wear of Sialon ceramic cutting tool, but its notch wear value VN is far less than Al2O3-SiCw whisker reinforced ceramic cutting tool,the main failure form of WG300 notch wear, the main failure form of SX9 for the flank wear.

Mechanical Properties and Microstructure of Self-Lubricating Ceramic Cutting Tool Materials

2004 ◽  
Vol 471-472 ◽  
pp. 221-224 ◽  
Author(s):  
Jian Xin Deng ◽  
Tong Kun Cao ◽  
Jia Lin Sun
Keyword(s):  
Mechanical Properties ◽  
Cutting Tool ◽  
Solid Lubricants ◽  
Polished Surface ◽  
Ceramic Tool ◽  
Tool Materials ◽  
Ceramic Cutting Tool ◽  
Micro Cracks ◽  
The Difference ◽  
Cutting Tool Materials

Al2O3/TiC ceramic tool materials with the addition of solid lubricants such as BN and CaF2 were produced by hot pressing. Effect of the solid lubricants on the microstructure and mechanical properties has been studied. Results showed that AlN phase resulted from the reaction of Al2O3 with BN was formed in Al2O3/TiC/BN composite after sintering. Significant micro-cracks resulted from the residual stress owing to the difference in the thermal expansion coefficient were found on the polished surface, and caused large mechanical properties degradation. While Al2O3/TiC/CaF2 composite showed higher flexural strength, fracture toughness, and hardness compared with that of Al2O3/TiC/BN composite owing its porosity absent and finer microstructure.

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.

New Experimental Expression of Durability Dependence for Ceramic Cutting Tool

2013 ◽  
Vol 275-277 ◽  
pp. 2230-2236 ◽  
Author(s):  
Anton Panda ◽  
Ján Duplák ◽  
Jozef Jurko ◽  
Marcel Behún
Keyword(s):  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Test Method ◽  
Durability Test ◽  
Technical Science ◽  
Ceramic Cutting Tool ◽  
Technical Practice ◽  
Complex Process ◽  
Experimental Expression

Durability of the cutting tools is very complex process that is influenced by more factors. To the Identify these factors is necessary execute many experiments. The technical science defines the basic method for determining durability of the cutting tool according to results and knowledge F. W. Taylor. The Literature from renowned authors indicates that durability of the cutting tool is defined on the base of T-vc dependence. T-vc dependence like a elementary durability dependence was described according to Taylor´s graphics dependence VB=f(s) for different cutting speeds in 1906. From this theory were later derived others theories, that became the basis of theories durability of cutting wedge for the different cutting materials. For the durability identification of the cutting tool are in technical practice used two basic tests. The First is the short-term durability test and second is machining long-term test method. Both these tests have some advantages and some disadvantages that are described in Introduction of this paper. This paper describes how to create and analytically express new durability dependence for ceramic cutting tool on the base of vc-VB dependence. This dependence consists from vc - cutting speed and VB - criterion of blunting. The whole procedure and its analytical expression is the subject of this paper.

scholarly journals CUTTING TOOL PERFORMANCE IN TURNING OF AL 7075-T651 ALUMINIUM ALLOY

2020 ◽  
Vol 21 (2) ◽  
pp. 177-185
Author(s):  
Natasha A. Raof ◽  
Nur Sofwati Daud @Ab Aziz ◽  
Abdul Rahman A. Ghani ◽  
Aishah Najiah Dahnel ◽  
Suhaily Mokhtar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Aluminium Alloy ◽  
Wear Mechanism ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Tool Wear Rate ◽  
Tool Performance ◽  
Al 7075

 Recently, almost 70% of a commercial jetliner’s airframe is made of aluminium alloys. It is predicted that the application of aluminium alloy is to increase up to 65% by the year 2025. They are typically used because of their high strength to weight ratio. However, there are some drawbacks during machining aluminium alloy such as the adhesion wear and built-up edge (BUE) formation that can shorten tool life. As the tool wears, the machining performance, surface roughness, and cutting tool life are affected significantly. A lot of studies were conducted in order to minimize this critical issue. This project presents a study of the cutting tool performance of an uncoated carbide tool in dry turning operation on Al 7075-T651, in which the tool wear rate, volume of material removed, wear mechanism, and surface roughness were investigated. The machining tests were conducted on a CNC lathe machine to obtain the tool wear and surface roughness of the machined work piece. The average flank wear was measured using a digital microscope, whereas the wear mechanism was observed using a Scanning Electron Microscope (SEM). The average surface roughness (Ra) was measured using a surface roughness tester. The cutting time for this experiment was fixed at 40 minutes and all the results were analysed within this time range to evaluate the tool performance in the turning of Al 7075-T651. The results revealed that the tool performs better at low cutting speed, 250 m/min, by reducing the tool wear rate by 33%. The cutting speed of 250 m/min also contributed to 71% higher volume of material removed during the machining tests. The dominant type of wear found was flank wear, while the main principal of wear mechanism is adhesion. At higher cutting speed, the surface roughness was improved. Based on the results, it can be concluded that high cutting tool performance is achieved when low tool wear growth rate, high volume of material removal, and low surface roughness during turning operation are obtained. ABSTRAK: Kebelakangan ini, hampir 70% kerangka pesawat udara komersil diperbuat daripada aloi aluminium. Penggunaan aloi aluminum ini dijangka meningkat sehingga 65% pada tahun 2025. Ia biasa digunakan kerana nisbah kekuatan kepada berat yang tinggi. Walau bagaimanapun, terdapat beberapa kekurangan semasa pemesinan aloi aluminum ini iaitu pemakaian pelekat dan pembentukan binaan tepi (BUE) yang mengurangkan jangka hayat mata alat. Apabila mata alat menjadi haus, prestasi mesin, kekasaran permukaan, dan jangka hayat mata alat pemotong terjejas dengan ketara. Banyak kajian telah dijalankan bagi mengurangkan isu kritikal ini. Projek ini mengkaji prestasi mata alat pemotong karbida tidak bersalut dalam operasi mesin larik kering pada Al 7075-T651, di mana kadar haus mata alat, kuantiti bahan yang dibuang, mekanisme haus dan kekasaran permukaan telah diselidiki. Ujian pemesinan dijalankan pada mesin CNC mesin larik bagi mendapatkan kadar haus mata alat dan kekasaran permukaan material yang dimesin. Purata haus pengapit mata alat diukur dengan menggunakan mikroskop digital, manakala mekanisme haus dipantau menggunakan Mikroskop Elektronik Pengimbas (SEM). Purata kekasaran permukaan (Ra) diukur menggunakan alat penguji kekasaran permukaan. Tempoh masa pemotongan bagi eksperimen ini telah ditetapkan pada 40 minit dan semua keputusan telah dianalisa dalam tempoh masa ini bagi menilai prestasi mata alat dalam melarik Al 7075-T651. Hasil menunjukkan prestasi mata alat lebih baik pada kelajuan pemotongan rendah, 250 m/min dengan mengurangkan kadar haus mata alat sehingga 33%. Kelajuan pemotongan 250 m/min juga menyumbang kepada 71% peningkatan ke atas jumlah bahan yang dibuang semasa ujian pemesinan. Jenis haus yang dominan telah ditemui pada pengapit mata alat, manakala mekanisme haus yang utama adalah lekatan. Pada kelajuan pemotongan yang tinggi, kekasaran permukaan didapati lebih baik. Berdasarkan keputusan, dapat disimpulkan bahawa prestasi mata alat pemotong yang bagus dapat dicapai apabila kadar haus mata alat adalah rendah, jumlah penyingkiran bahan yang tinggi dan kekasaran permukaan yang rendah semasa operasi pelarikan dijalankan. ABSTRAK: Kebelakangan ini, hampir 70% kerangka pesawat udara komersil diperbuat daripada aloi aluminium. Penggunaan aloi aluminum ini dijangka meningkat sehingga 65% pada tahun 2025. Ia biasa digunakan kerana nisbah kekuatan kepada berat yang tinggi. Walau bagaimanapun, terdapat beberapa kekurangan semasa pemesinan aloi aluminum ini iaitu pemakaian pelekat dan pembentukan binaan tepi (BUE) yang mengurangkan jangka hayat mata alat. Apabila mata alat menjadi haus, prestasi mesin, kekasaran permukaan, dan jangka hayat mata alat pemotong terjejas dengan ketara. Banyak kajian telah dijalankan bagi mengurangkan isu kritikal ini. Projek ini mengkaji prestasi mata alat pemotong karbida tidak bersalut dalam operasi mesin larik kering pada Al 7075-T651, di mana kadar haus mata alat, kuantiti bahan yang dibuang, mekanisme haus dan kekasaran permukaan telah diselidiki. Ujian pemesinan dijalankan pada mesin CNC mesin larik bagi mendapatkan kadar haus mata alat dan kekasaran permukaan material yang dimesin. Purata haus pengapit mata alat diukur dengan menggunakan mikroskop digital, manakala mekanisme haus dipantau menggunakan Mikroskop Elektronik Pengimbas (SEM). Purata kekasaran permukaan (Ra) diukur menggunakan alat penguji kekasaran permukaan. Tempoh masa pemotongan bagi eksperimen ini telah ditetapkan pada 40 minit dan semua keputusan telah dianalisa dalam tempoh masa ini bagi menilai prestasi mata alat dalam melarik Al 7075-T651. Hasil menunjukkan prestasi mata alat lebih baik pada kelajuan pemotongan rendah, 250 m/min dengan mengurangkan kadar haus mata alat sehingga 33%. Kelajuan pemotongan 250 m/min juga menyumbang kepada 71% peningkatan ke atas jumlah bahan yang dibuang semasa ujian pemesinan. Jenis haus yang dominan telah ditemui pada pengapit mata alat, manakala mekanisme haus yang utama adalah lekatan. Pada kelajuan pemotongan yang tinggi, kekasaran permukaan didapati lebih baik. Berdasarkan keputusan, dapat disimpulkan bahawa prestasi mata alat pemotong yang bagus dapat dicapai apabila kadar haus mata alat adalah rendah, jumlah penyingkiran bahan yang tinggi dan kekasaran permukaan yang rendah semasa operasi pelarikan dijalankan.

Evaluation of the cutting forces, the surface roughness, and the tool wear characteristics during machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool

2021 ◽  
pp. 095440892110480
Author(s):  
Abdullah Altin
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Signal To Noise ◽  
Ceramic Cutting Tool ◽  
Cutting Speeds

In this research, we had studied the sensitivity for machining of cobalt-based superalloy Haynes 188 with ceramic cutting tool. The investigation had focused on the effects of the cutting speed, on the cutting forces, and on the surface roughness based on Taguchi’s experimental design. The effects of machining parameters were determined using Taguchi’s L27 orthogonal array. The signal-to-noise ratio was calculated for the average of surface roughness and the cutting forces, and the smaller were used to determine the optimal cutting conditions. The analysis of variance and the signal-to-noise ratio had effects on the parameters on both surface roughness and cutting. Three different types of cutting tools had been used in the experiment, namely KYON 4300, KYS 25, and KYS 30. The cutting force of Fz was considered to be the main cutting force. Depending on the material which had been used as cutting tool, the Fz had the lowest cutting speed and the lowest surface roughness with the KYS25 ceramic tool. The cutting force and the surface roughness of KYON 4300 cutting tool had shown better performance than other cutting tools. The flank wear and notch were found to be more effective in the experiments. The long chips were removed at low and medium cutting speeds, while the sawdust with one edge and narrow pitch at high cutting speeds was obtained.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

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