Studies on Si3N4 Ceramic Cutting Tool Materials and their Applications

1992 ◽  
Vol 287 ◽  
Author(s):  
He-Zhuo Miao ◽  
Long-Hao Qi ◽  
De-Jin Ma ◽  
Zuo-Zhao Jiang
Keyword(s):  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Particle Dispersion ◽  
Phase Hardening ◽  
Dispersion Phase ◽  
Hard Materials ◽  
Cemented Carbide Tools ◽  
Cutting Behavior ◽  
Cutting Tool Materials

ABSTRACTSi3N4 ceramics are excellent metal cutting materials. The cutting behavior can be improved by hard particle dispersion phase hardening and heat treatment so as to reduce glass phase in the grain boundaries. Compared with cemented carbide tools, the cutting life of the composite Si3N4 cutting tool is about 10-100 times longer, and the optimum cutting speed is about 3-10 times faster. It performs well in cutting hardened tools, nickel based alloys, and other hard materials and can sustain shock loads in operations such as milling, planing and other types of interrupted cutting. Applications in various fields show that machining efficiency can be increased by 3-10 times resulting in savings of time, electricity, and machining of 30-70% or even more.

Hard Nano-Crystalline Coatings for Cutting Tools

2007 ◽  
Vol 567-568 ◽  
pp. 185-188 ◽  
Author(s):  
Miroslav Piska
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Dry Cutting ◽  
Nano Crystalline ◽  
The Right ◽  
Machining Productivity ◽  
Hard Cutting ◽  
Cutting Tool Materials

Modern trends in metal cutting, high speed/feed machining, dry cutting and hard cutting set more demanding characteristics for cutting tool materials. The exposed parts of the cutting edges must be protected against the severe loading conditions and wear. The most significant coatings methods for cutting tools are PVD and CVD/MTCVD today. The choice of the right substrate or the right protective coating in the specific machining operation can have serious impact on machining productivity and economy. In many cases the deposition of the cutting tool with a hard coating increases considerably its cutting performance and tool life. The coating protects the tool against abrasion, adhesion, diffusion, formation of comb cracks and other wear phenomena.

Grey-Based Taguchi Analysis Approach for Optimization of Multi-Objective Problem

2014 ◽  
pp. 219-239
Author(s):  
Nirmal S Kalsi ◽  
Rakesh Sehgal ◽  
Vishal S. Sharma
Keyword(s):  
Feed Rate ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Removal Rate ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Multi Objective ◽  
Analysis Technique ◽  
Grey Relation

Due to the increase in complexity and expectations of more reliable solutions for a problem, the importance of multi-objective problem solutions is increasing day by day. It can play a significant role in making a decision. In the present approach, many combinations of the optimization techniques are proposed by the researchers. These hybrid evolutionary methods integrate positive characteristics of different methods and show the advantage to reach global optimization. In this chapter, Taguchi method and the GRA (Grey Relation Analysis) technique are pronounced and used to optimize a multi-objective metal cutting process to yield maximum performance of tungsten carbide-cobalt cutting tool inserts in turning. L18 orthogonal array is selected to analyze the effect of cutting speed, feed rate, and depth of cut using cryogenically treated and untreated inserts. The performance is evaluated in terms of main cutting force, power consumption, tool wear, and material removal rate using main effect plots of S/N (Signal to Noise) ratios. This chapter indicates that the grey-based Taguchi technique is not only a novel, efficient, and reliable method of optimization, but also contributes to satisfactory solution for multi-machining objectives in the turning process. It is concluded that cryogenically treated cutting tool inserts perform better. However, the feed rate affects the process performance most significantly.

Transient Thermal Stresses in the Quarter-Plane and their Relation to the Thermal-Cracking of Cutting Tools

1974 ◽  
Vol 16 (5) ◽  
pp. 322-330
Author(s):  
P. F. Thomason
Keyword(s):  
Metal Cutting ◽  
Thermal Stresses ◽  
Cutting Tool ◽  
Crack Nucleation ◽  
Cutting Tools ◽  
Thermal Cracking ◽  
Quarter Plane ◽  
Metal Cutting Tool ◽  
Transient Thermal ◽  
Cemented Carbide Tools

The transient thermal stresses in an insulated quarter-plane, subject to an instantaneous heat source on a segment of the surface, are determined with the aid of the Green's function for a two-dimensional infinite space. Numerical results for the transient thermal stresses at the surfaces of the quarter-plane are superimposed on previous isothermal results for cutting-load stresses in a π/2 wedge, to provide a model for a metal-cutting tool in the transient stages of a cutting process. The results are related to the problem of the thermal-cracking of cutting tools, and mechanisms of crack nucleation and propagation are proposed for both ceramic and cemented-carbide tools.

scholarly journals Influence of machining conditions on friction in metal cutting process – A review

Mechanik ◽  
2019 ◽  
Vol 92 (4) ◽  
pp. 242-248
Author(s):  
Wit Grzesik ◽  
Joel Rech
Keyword(s):  
Tool Wear ◽  
Contact Zone ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Sliding Velocity ◽  
Contact Conditions ◽  
Tool Materials ◽  
Cutting Zone ◽  
Cooling Media ◽  
Cutting Tool Materials

This paper presents a range of variable machining factors which influence substantially friction directly or by the tool wear developed in the cutting zone. The group of direct factors include the workpiece and cutting tool materials coupled, the cutting/sliding velocity, cooling media supplied to the tool-chip contact zone, modification of the tool contact faces by micro-texturing. Special attention was paid to the tool wear evolution and its pronounced effect on changes of the contact conditions.

Research on Drilling of Ni-Based Powder Metallurgy Superalloys

2016 ◽  
Vol 693 ◽  
pp. 680-685 ◽  
Author(s):  
Wang Hui ◽  
Pei Quan Guo ◽  
Yang Qiao ◽  
Jin Tao Niu
Keyword(s):  
Powder Metallurgy ◽  
Failure Modes ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cost Effective ◽  
Drilling Process ◽  
Twist Drill ◽  
Optimal Parameters ◽  
Tool Materials ◽  
Cutting Tool Materials

The application of Ni-based powder metallurgy superalloys materials was limited for its' difficult-to-machine, such as excessive tool wear, frequent tool change, short tool life, low productivity, and large amount of power consumption etc. So the studying of Ni-based powder metallurgy superalloys drilling process becomes extremely important. This paper mainly introduces the research status of drilling of Ni-based powder metallurgy superalloys materials and through synthesize considering cutting force and cost effective, we determined the optimal of cutting tool materials is carbide YG8 twist drill. The optimal parameters of drilling of Ni-based powder metallurgy superalloys: cutting speed of 15m/min, feed per tooth of 0.02mm/r. When the superalloys material is machined by standard twist drill, it is always appearing the failure modes of drilling.

Study on Wear Mechanism of Carbide Tool in Machining Inconel 718

2013 ◽  
Vol 589-590 ◽  
pp. 323-326 ◽  
Author(s):  
Yi Hang Fan ◽  
Liang Zhou ◽  
Shuang Zhu Song ◽  
Feng Lian Sun
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Wear Debris ◽  
Oxidation Reaction ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Tool Breakage ◽  
Nickel Based Superalloy ◽  
Cemented Carbide Tools

Tool wear is a problem in machining nickel-based superalloy Inconel 718, and it is thus of great importance to understand and quantitatively predict tool wear. The experiments of machining Inconel 718 with cemented carbide tools (uncoated and coated) were carried out. Some new observations and analysis of tool wear through CCD, SEM and EDS were done. The results showed that at low cutting speed, the built up edge (BUE) formed easily and dropped at last which caused severe cutting tool breakage. When cutting speed came to 30m/min, the main reason that caused cutting tool wear was that the tool material fell off from the tool body at the form of wear debris. What’s more, the element diffusion between tool and workpiece and oxidation reaction all accelerate the formation and the cast of the wear debris.

Metal Oxycarbides as Cutting Tool Materials

1976 ◽  
Vol 98 (1) ◽  
pp. 279-286 ◽  
Author(s):  
W. W. Carson ◽  
C. L. Leung ◽  
N. P. Suh
Keyword(s):  
Chemical Stability ◽  
Cutting Tool ◽  
Chemical Interaction ◽  
Free Energies ◽  
Wear Process ◽  
Tool Materials ◽  
Coated Tools ◽  
Free Energy Of Formation ◽  
Cemented Carbide Tools ◽  
Cutting Tool Materials

The role of chemical stability of cutting tool materials in tool wear was investigated by studying the wear characteristics of titanium oxycarbides. The oxycarbides TiC0.25O0.75, TiC0.5O0.5, TiC0.6O0.4, and TiC0.75O0.25 were produced by solid state interdiffusion of TiO and TiC. Their hardnesses and lattice spacings were determined as functions of their chemical composition. The chemical interaction of these oxycarbides with steel was investigated by diffusion couple experiments. Then commercially available cemented carbide tools were coated with TiC0.5O0.5 and TiC0.75O0.25 by RF diode sputtering. The wear resistance of these coated tools was determined by cutting tests. The wear rate of these oxycarbide coated tools was comparable to that of a TiC coated tool, although the free energies of formation of oxycarbides were lower and their hardnesses comparable. It is, therefore, concluded that while the data on free energy of formation and hardness can be useful in the initial screening steps of tool materials, the kinetics of the wear process needs to be more fully understood to define the chemical stability of tool materials in a cutting environment.

scholarly journals EFFECT OF CUTTING SPEED IN THE TURNING PROCESS OF AISI 1045 STEEL ON CUTTING FORCE AND BUILT-UP EDGE (BUE) CHARACTERISTICS OF CARBIDE CUTTING TOOL

SINERGI ◽  
2020 ◽  
Vol 24 (3) ◽  
pp. 171
Author(s):  
Sobron Yamin Lubis ◽  
Sofyan Djamil ◽  
Yehezkiel Kurniawan Zebua
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Aisi 1045 Steel ◽  
1045 Steel

In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.

Hard-alloy metal-cutting tool for the finishing of hard materials

2017 ◽  
Vol 37 (2) ◽  
pp. 148-149
Author(s):  
D. S. Rechenko ◽  
A. Yu. Popov ◽  
D. Yu. Belan ◽  
A. A. Kuznetsov
Keyword(s):  
Hard Alloy ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Hard Materials ◽  
Metal Cutting Tool ◽  
Alloy Metal

Comparison Vibration Amplitude for Magnetic Damping in Turning of Stainless Steel AISI 304

2013 ◽  
Vol 394 ◽  
pp. 251-255 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Ummu Atiqah Khairiyah Bt. Mohamad ◽  
Muammer D. Arif ◽  
Asan Gani Bin Abdul Muthalif
Keyword(s):  
Stainless Steel ◽  
Metal Cutting ◽  
Permanent Magnets ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Work Piece ◽  
Aisi 304 ◽  
Cutting Stability ◽  
Steel Aisi ◽  
Stainless Steel Aisi

This paper presents the improvement in chatter vibration damping using different types and arrangements of magnets, as well as comparison with normal cutting conditions in turning of stainless steel AISI 304. Chatter is defined as the self-excited violent relative motion between the cutting tool and work-piece. It is the common vibration problem that limits the productivity of machining processes, since it leads to shortened tool life, poor surface finish, breakage and premature damage of cutting tool, as well as mechanical deterioration. The occurrence of chatter during metal cutting process also causes instability of the machine tool system. Though there has been a large number of works on identifying the causes of chatter and its behavior, there is still no consensus among researchers on this very vital issue of machining. Previously, the incidence of chatter was thought to be due to forced vibration, BUE formation, cutting speed, and cracking during chip formation. Different ways to overcome this problem have been investigated, such as using piezoelectric inertia actuators, feed-forward neural network controllers, and work-piece preheating methods. In this research, permanent magnets with different size, strength, and composition are mounted around the cutting tool. A vibration sensor (accelerometer) is placed at the bottom of the tool to record the suppression of chatter amplitude in turning operation. It is shown that magnetic force can modify the frequency response function of the cutting tool resulting in improved cutting stability in turning operations. Chatter can then be effectively suppressed due to increased cutting stability.

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