scholarly journals Assessment of selected properties of treated tool surfaces examined to increase tool life time

2020 ◽  
Vol 20 (2) ◽  
pp. 257-264
Author(s):  
Miroslava Ťavodová ◽  
Richard Hnilica
Keyword(s):  
Tool Life ◽  
Life Time ◽  
Increase Tool Life

scholarly journals The Design and Implementation of Fan Chips as Cooling for Milling Process on Aluminum Alloy 5086 to Increase Tool Life

2021 ◽  
Vol 2 (1) ◽  
pp. 29-42
Author(s):  
Agus Sifa ◽  
Dedi Suwandi ◽  
Tito Endramawan ◽  
Alam Aulia Rachman
Keyword(s):  
Aluminum Alloy ◽  
Tool Life ◽  
Experimental Testing ◽  
Fluid Dynamic ◽  
Milling Process ◽  
Machining Process ◽  
Central Character ◽  
Spindle Rotation ◽  
Cfd Method ◽  
Increase Tool Life

In the metal machining process, especially in the milling process, the parameters that affect the quality milling process results are cooling media because it affects the tool life used. This paper aims to determine the performance of using fan chips as the coolant in the dry milling process area. The method used is the computational fluid dynamic (CFD) method and the experimental milling process on a workpiece made from aluminum alloy 5086. In experimental testing using a variation of the milling machine spindle rotation. The simulation test results on the fluid flow character on fan chips with a protector producing a central character with a small area. In contrast, fan chips without a protector make a central character with a broader area. The wind speed data in simulation testing and experimental testing produced the same trend graph. The results of the performance of fan chips after experimented with variations in spindle rotation, cooling process on area occurs when the motor spindle rotates above 1120 Rpm on the fan chips with a protector, and the engine spindle rotates above 770 Rpm on the fan chips without a protector. The effect of fan chips on tool life affects increasing tool life by 8 minutes on installing fan chips with a protector and increasing tool life by 12 minutes on installing fan chips without a protector.

scholarly journals Threading Performance of Different Coatings for High Speed Steel Tapping

Coatings ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 464
Author(s):  
Alain Gil Del Val ◽  
Fernando Veiga ◽  
Octavio Pereira ◽  
Luis Norberto Lopez De Lacalle
Keyword(s):  
Tool Life ◽  
Vapor Deposition ◽  
Physical Vapor Deposition ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Tialn Coating ◽  
Tool Performance ◽  
Thread Profile ◽  
Increase Tool Life

Threading holes using tapping tools is a widely used machining operation in the industry. This manufacturing process involves a great tool immersion in the part, which involves both friction and cutting. This makes the use of coatings critical to improving tool life. Four coatings are used based on Physical vapor deposition (PVD) technology—TiN, TiCN, TiAlN and TiAlN+WC/C are compared to uncoated tool performance. The effect of various coatings on the life of M12 × 1.5 tapping tools during threading of through holes 20 mm deep, in GG25 casting plates, dry and applying cutting speed of 50 m/min. The end-of-life criterion has been established based on a cutting torque of 16 N-m. Taking the uncoated tap as a basis for comparison, it is observed that coatings based on PVD technologies increase tool life doubling in the most advantageous case with the TiAlN coating. PVD type coatings provide better protection to wear at cylindrical area of the tool, where the thread profile is finished, than uncoated taps. The teeth located in the cone-cylinder transition zone of the taps suffer the most wear regardless of the coating. However, taps coated with TiAlN+WC/C wear level values is lowest of all the coatings tested, which indicates a strong reinforcement in these teeth.

Evaluating the use of high-pressure coolant in turning process of Inconel 625 nickel-based alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1182-1192 ◽  
Author(s):  
Aristides Magri ◽  
Anselmo Eduardo Diniz ◽  
Daniel Iwao Suyama
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Tool Life ◽  
Weight Ratio ◽  
Inconel 625 ◽  
Mechanical Resistance ◽  
Machining Processes ◽  
Nickel Based Alloy ◽  
Increase Tool Life ◽  
High Pressure Coolant

The automotive, aerospace and energy industries have lately increased their search for materials which must have high mechanical resistance/weight ratio and capability to maintain the mechanical properties in high temperatures and at corrosive environments in order to produce critical parts of their equipment. The nickel-based alloys are one type of materials which have been a good answer for this search. On the other hand, the very good mechanical properties of these alloys make their manufacturing very difficult, especially when machining processes are used. Among other problems in the machining of these alloys, due to the high mechanical resistance in high temperature, tool lives used to be much shorter than when steel alloys are machined, forcing cutting speeds to be much lower and, consequently, to have less productive processes. The main goal of this work was to test an alternative to increase tool life in the turning of Inconel 625 nickel-based alloy by the use of high-pressure coolant. This system was tested using different directions of the fluid flow (toward the rake face, toward the flank face and directing the fluid simultaneously toward these two tool faces) compared to the conventional way of applying fluid. The results show that the use of high-pressure coolant harms the notch wear development and, consequently, increases tool life with simultaneous improvement of workpiece surface roughness in some cases. However, the application of high-pressure coolant over both flank and rake faces at the same time did not provide any improvement.

Experimental Design Applied to the Machining of Windows Cage Ball Joints Homokinetic SAE 8620 Steel with CBN Tool

2011 ◽  
Vol 223 ◽  
pp. 573-578
Author(s):  
Nivaldo Lemos Coppini ◽  
José C. C. Santana ◽  
Elesandro Antonio Baptista ◽  
Daniel B. da Rosa ◽  
Aroldo Alcantara
Keyword(s):  
Tool Life ◽  
Cutting Speed ◽  
Life Time ◽  
Steel Part ◽  
Hyperbolic Model ◽  
23 Factorial Design ◽  
Cbn Tool ◽  
Processing Optimization ◽  
Ball Joints ◽  
Sae 8620 Steel

In this work a factorial planning had been used to evaluate the CBN tool life during cut-ting SAE 8620 steel. Part U2222 of a TPGW 160408 insert of TX-LS TB650 and 2NU-SHMA6942 S7182BN300 classes from two manufacturers were used in this experiment. A 23 factorial design was used In cutting process to evaluate the behavior of the tool life and reason of the exchange of the part on influences of the chamfer (in S and T+S), the advancing speeds (0.09, 0.10 and 0.11 mm/rpm) at a cutting speed of 91.2 m/min. Model have been fit by variance analysis (ANOVA) and the processing optimization was done by response surface methodology (RSM). Results showed that a hyperbolic model had more adjusting than other models and the optimization showed a high life time for the TX-LS TB650 tool from A manufacturer on 0.09 mm/rpm of advancing speed, where it was observed that the pre-cranking was the reason of the exchange.

scholarly journals Study of the Wear of the Cutting Edge of Milling Heads

2014 ◽  
Vol 11 (2) ◽  
pp. 32-37
Author(s):  
Dana Stancekova ◽  
Jozef Pilc ◽  
Jozef Struharnansky ◽  
Miroslav Janota ◽  
Daniel Varga
Keyword(s):  
Tool Life ◽  
The State ◽  
Cutting Edge ◽  
Primary Contact ◽  
Milling Tool ◽  
Increase Tool Life ◽  
Milling Tools ◽  
Primary Interaction

Abstract The article deals with analysis of the charakter of the interaction of milling tools with cutting edges of the primary contact with the working materials. Based on the monitoring of wear is observed various charakter and intensity of wear of the cutting wedge, which is dependent on the position of the milling tool frame to the workpiece. Given the issue is analyzed in the state, according to the proposed method is the primary interaction of tool and workpiece milling tool, in order to increase tool life.

Turning of SAE 1050 Steel With Vegetable Base Cutting Fluid

2012 ◽  
Author(s):  
Rosemar Batista da Silva ◽  
Álisson Rocha Machado ◽  
Déborah de Oliveira Almeida ◽  
Emmanuel O. Ezugwu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Manufacturing Companies ◽  
Machining Performance ◽  
Increase Tool Life

The study of cutting fluid performance in turning is of great importance because its optimization characteristics has associated benefits such as improved tool life and overall quality of machined components as well as reduction in power consumption during machining. However, there are recent concerns with the use of cutting fluids from the environmental and health standpoints. Since environmental legislation has become more rigorous, the option for “green machining” attracts the interest of several manufacturing companies. It is important to consider the cost of machining which is associated with tool wear, depending on the cutting environment. The use of vegetable oil may be an interesting alternative to minimize the health and environmental problems associated with cutting fluids without compromising machining performance. This paper presents a comparative study of mineral and vegetable cutting fluids in terms of tool wear after turning SAE 1050 steel grade with cemented carbide cutting tools. Constant depth of cut of 2mm and variable cutting speed (200 and 350 m/min) and feed rate (0.20 and 0.32 mm/rev) were employed. Test results suggest that is possible to achieve improvement in machinability of the material and increase tool life by using vegetable cutting fluid during machining. Tool life increased by about 85% when machining with vegetable-based fluids compared to mineral-based fluids. Analysis of the worn tools, however, revealed a more uniform wear on the worn flank face when machining with mineral-based fluids.

Waterjet Turning of Titanium Alloys

2013 ◽  
Vol 769 ◽  
pp. 77-84
Author(s):  
Karsten Flögel ◽  
Fabian Faltin
Keyword(s):  
Titanium Alloys ◽  
Tool Life ◽  
Material Removal Rate ◽  
Manufacturing Process ◽  
Material Removal ◽  
Removal Rate ◽  
Life Time ◽  
Abrasive Waterjet ◽  
Rough Turning ◽  
Setting Parameters

Titanium alloys offer outstanding properties with regard to its strength to density ratio and a good corrosive resistance in air atmospheres. Substantial advancements could be made by using titanium alloys, in particular for applications in the aerospace industry and medical engineering. However, no product innovation is possible without an appropriate machining technology. For example, low thermal conductivity and hot hardness lead to limitations regarding the applicable machining parameters, particularly for continuous cutting operations. Turning of high performance materials sets high demands on machine tools and especially on the used cutting tools. For conventional continuous cutting of titanium alloys the tool life time and therefore the tool life volume is limited due to the thermal mechanical behaviour. Depending on the chemical and structural composition of the alloy, conventional cutting operations can rarely be regarded as an economic solution. The Abrasive Waterjet Turning process (AWJT) represents a promising alternative manufacturing method to produce rotation-symmetrically or helical parts made of difficult to machine materials. The AWJT process combines the kinematics of conventional turning methods with process-specific advantages of the abrasive waterjet machining. The main advantages are the high variety of machinable materials, the long life time T of the focus nozzles of at least 300 minutes and its independence of the material to be processed. Furthermore, material-inhomogeneity or the initial geometrical contour of the workpiece cannot result in tool failures. An interaction of workpiece and tool known from conventional cutting processes cannot occur. An investigation on hyper eutectic aluminium alloys has shown that AWJT is an economic manufacturing process regarding the resulted material removal rates Qw and tool life volumes. The resulting roughnesses and roundnesses are comparable to a rough turning operation. In addition, AWJT results in a lower hardness penetration depth tw in comparison to conventional turning. Machining of titanium alloys with cylindrical and external turning operations as well as grooving is the next step in the experimental investigation of the machinability of difficult to machine materials with AWJT. Therefore, the objective of the presented work is to provide a model for predicting the material removal rate, the cylindrical roundness and the surface roughness of waterjet turning of the titanium alloy Ti6Al4V. In a screening experiment the significant setting parameters were identified and an adequate range of parameter settings for the response surface study was determined. The tested parameters were the feed rate vf, the abrasive flow rate m and particle size dp, the depth of cut dc and the rotational speed n of the workpiece. It is shown that in relation to the material removal rate Qw linear main effects as well as interaction effects are significant. The developed second-order-regression-model includes these linear main and interaction effects and the quadratic effects of the relevant setting parameters. Furthermore, the achieved material removal rates, tool life volumes, cylindrical roundness and surface quality are used as target values. Additionally the changes like plastic deformations and grain damages in the rim zone were compared to conventional machined parts. Relating to the material removal rate Qw, up to 2.5 cm³/min could be achieved for AWJT at a maximum height of profile Rz below 100 microns. Furthermore, the investigation resulted in a maximum tool life volume of 750 cm³ at a given nozzle life time. The results show that AWJT can be used as an economic alternative manufacturing process for rough turning of titanium alloys.

Qualification of Coatings to Predict Wear Behavior of Micro Blasted Cutting Tools

2010 ◽  
Vol 438 ◽  
pp. 23-29 ◽  
Author(s):  
Fritz Klocke ◽  
Christof Gorgels ◽  
Arne Stuckenberg ◽  
Emmanouil Bouzakis
Keyword(s):  
Tool Life ◽  
Zirconium Oxide ◽  
Cutting Tool ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Production Engineering ◽  
Coating Technology ◽  
Testing Method ◽  
Increase Tool Life ◽  
Tool Treatment

In today’s production engineering nearly every cutting tool is coated. In the field of coating technology and tool treatment blasting is a common way to increase tool life or hold it on a constant level for several reconditioning steps. The latest innovation referring blasting are micro blasted coatings. For this technology a parameter variation was examined and the consequential tool life was compared with common testing method for tool systems in order to qualify the coating treatment. The investigations were carried out using an aluminum and zirconium oxide as blasting abrasive and by varying the blasting parameters pressure and duration. Finally, the treatment led to an optimized tool wear behavior due to micro blasting of the coating and the wear behavior could be referenced against the testing methods.

scholarly journals Correlations between Forging Tool Lifetime and the Continuous Curvature Transitions

2019 ◽  
Vol 12 (4) ◽  
pp. 306-320
Author(s):  
Tamás Ibriksz ◽  
Ferenc Tancsics
Keyword(s):  
Tool Life ◽  
Process Parameters ◽  
Work Piece ◽  
Technical Device ◽  
Real Geometry ◽  
Continuous Curvature ◽  
Increase Tool Life ◽  
Classical Optimization

The forged work-piece geometry is determined by different standards and bilateral specifications, so the geometry is not allowed to be changed by the technologist according to their own decision.  Therefore, the lifetime of the tool which gives the final geometry is a key issue. The tool lifetime is mainly influenced by technology and process parameters. Regarding these parameters, there are many classical optimization solutions available to increase tool life. In our work, we have looked for a technical device that can complement classic solutions to further enhance the effectiveness in the field of forging tools lifetime. In our opinion, such a technical device may be a continuous curvature of the surface transitions at the preformed geometry. In our work, we investigated the effect of the continuous curvature for a function reducing the forging work at a real geometry.

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