scholarly journals Tool Quality Life during Ball End Milling of Titanium Alloy Based on Tool Wear and Surface Roughness Models

2020 ◽  
Vol 10 (9) ◽  
pp. 3316
Author(s):  
Zemin Zhao ◽  
Xianli Liu ◽  
Caixu Yue ◽  
Rongyi Li ◽  
Hongyan Zhang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Design ◽  
Service Performance ◽  
Time Varying ◽  
Tool Performance ◽  
Quality Life ◽  
Milling Tool ◽  
Tool Service ◽  
The Relationship

The prediction and control of milling tool service performance is critical for milling tool design and machining. However, the existing prediction model can hardly quantify tool performance, or precisely describe the relationship between the tool performance and the design or milling parameters. This study redefines the tool lifetime as a function of surface roughness and proposes a new geometric analysis method based on a time-varying wear model. The proposed method can be utilized to evaluate the relationship between tool wear and lifetime. The surface roughness, with respect to tool service performance, is expressed as a time-varying model of the tool and processing parameters. After experimental validation, the influence factors were analyzed through simulation. A generalized method for milling tool design was proposed and successfully applied to a tool performance design case, on a theoretical level. Additionally, the research results prove that basing the tool milling quality life on the surface roughness is extremely feasible and necessary.

Study of the Relationship between Tool Wear and Surface Finish in Turning with Carbide Tool

2014 ◽  
Vol 902 ◽  
pp. 95-100 ◽  
Author(s):  
Heraldo J. Amorim ◽  
Augusto O. Kunrath Neto
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Surface Finish ◽  
Cutting Speed ◽  
Single Equation ◽  
Carbon Steels ◽  
High Dispersion ◽  
Exponential Relationship ◽  
Processed Material ◽  
The Relationship

The aim of this work is to analyze the tool wear effects on surface finish of machined components. Long-term machinability tests were performed for ASTM 1040 and 1045 carbon steels with carbide tools, in which tool wear and surface roughness were periodically evaluated. Surface finish was analyzed as a function of processed material and cutting speed with new machining tool, and a significant influence was found for cutting speed at a confidence interval of 10%. When evaluated as a function of time and tool wear, surface roughness showed an exponential relationship with both variables. However, a high dispersion occurs close to the end of tool life, especially for AISI 1040 steel. Weak influence of cutting speed (for the range of speeds tested) was observed on the relationship between tool wear and surface finish, indicating that a single equation can describe its behavior for all studied conditions. The relationship between the surface roughness and the cutting time was found to be stronger for the ABNT 1040 steel.

Precision Cutting of Structured Ceramic Molds with Micro PCD Milling Tool

2011 ◽  
Vol 5 (3) ◽  
pp. 277-282 ◽  
Author(s):  
Hirofumi Suzuki ◽  
◽  
Tatsuya Furuki ◽  
Mutsumi Okada ◽  
Katsuji Fujii ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tungsten Carbide ◽  
Polycrystalline Diamond ◽  
Micro Milling ◽  
Grinding Wheels ◽  
Form Accuracy ◽  
Structured Surfaces ◽  
Milling Tool ◽  
Milling Tools

Micro milling tools made of PolyCrystalline Diamond (PCD) have been developed to machine ceramic micro dies and molds. Cutting edges are ground with diamond wheels. PCD milling tool wear is evaluated by cutting binder-less tungsten carbide spherical molds and machining structured surfaces for trial. Results of experiments clarified that PCD milling tool life is over 10 times that of resinoid diamond grinding wheels, and that form accuracy was 0.1 µm-0.3 µm P-V and surface roughness was 10 nm Rz.

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.

Combined effects of various materials on tool wear in drilling of Ti/CFRP stacks

2019 ◽  
Vol 234 (14) ◽  
pp. 2750-2759
Author(s):  
Qi Wang ◽  
Fuji Wang ◽  
Chong Zhang ◽  
Chen Chen
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Thrust Force ◽  
Cutting Tools ◽  
Cutting Edge ◽  
Combined Effects ◽  
Wear Process ◽  
Drill Bits ◽  
Tool Performance ◽  
The Relationship

Ti/CFRP stacks present the key function in the aviation field due to their excellent properties. However, both titanium alloy and CFRP are hard-to-cut materials and their requirements on cutting tool performance are significantly different. When drilling Ti/CFRP stacks using a compromised tool, tool wear is affected by two materials, resulting in extremely low tool life. This paper investigates the wear process of chisel edge and main cutting edge of carbide step drill bits in the drilling of Ti/CFRP stacks, titanium alloys and CFRP, and the combined effects of various materials on the tool wear are revealed. Based on the wear analysis, it is found that tool wear is more affected by the carbon fiber/Ti-adhesion interaction which makes the rake face more susceptible to occur adhesive wear and slows down the flank wear, and severe rake wear and flank wear have a sharpening effect on cutting edge. It also reveals the relationship between thrust force and tool wear, and results indicate that the variation of thrust force is related to the flank wear and the Ti-adhesion attached to chisel edge, but not to the edge rounding. The conclusions reported in this paper can provide guidance for structural optimization of long-life stacks cutting tools.

Time-varying analytical model of ball-end milling tool wear in surface milling

2020 ◽  
Vol 108 (4) ◽  
pp. 1109-1123 ◽  
Author(s):  
Zemin Zhao ◽  
Xianli Liu ◽  
Caixu Yue ◽  
Hongyan Zhang ◽  
Rongyi Li ◽  
...  
Keyword(s):  
Tool Wear ◽  
Analytical Model ◽  
End Milling ◽  
Time Varying ◽  
Ball End Milling ◽  
Milling Tool

Modeling and Prediction Research on End Mills Wear in Micro Turn-Milling Process

2013 ◽  
Vol 423-426 ◽  
pp. 741-745
Author(s):  
Xiao Yang Su ◽  
Zhi Jing Zhang ◽  
Xin Jin ◽  
Yong Jun Deng
Keyword(s):  
Tool Wear ◽  
Cutting Parameters ◽  
Milling Process ◽  
Visual Measurement ◽  
Modeling And Prediction ◽  
Milling Tool ◽  
End Mills ◽  
On Line ◽  
The Relationship ◽  
Turn Milling

An end mills wear experiment was designed to model and predict the end mills wear in micro turn-milling process. Based on the on-line visual measurement system, the tool wear was measured, then micro turn-milling tool wear regression models were established according to Response surface Method (RSM). The relationship between cutting parameters and tool wear was discussed in detail. The results indicate that the regression model can predict the value and regularity of end mills wear accurately, which can provide guidance on improving machining precision and quality in micro turn-milling process.

Possible examinations of stone machining focused on the relationship between technological parameters and surface quality

2013 ◽  
Vol 4 (1) ◽  
pp. 63-68 ◽  
Author(s):  
Zs. Kun ◽  
I. G. Gyurika
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Theoretical Background ◽  
Motion Path ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Technological Parameters ◽  
The Relationship ◽  
Manufacturing Time

Abstract The stone products with different sizes, geometries and materials — like machine tool's bench, measuring machine's board or sculptures, floor tiles — can be produced automatically while the manufacturing engineer uses objective function similar to metal cutting. This function can minimise the manufacturing time or the manufacturing cost, in other cases it can maximise of the tool's life. To use several functions, manufacturing engineers need an overall theoretical background knowledge, which can give useful information about the choosing of technological parameters (e.g. feed rate, depth of cut, or cutting speed), the choosing of applicable tools or especially the choosing of the optimum motion path. A similarly important customer's requirement is the appropriate surface roughness of the machined (cut, sawn or milled) stone product. This paper's first part is about a five-month-long literature review, which summarizes in short the studies (researches and results) considered the most important by the authors. These works are about the investigation of the surface roughness of stone products in stone machining. In the second part of this paper the authors try to determine research possibilities and trends, which can help to specify the relation between the surface roughness and technological parameters. Most of the suggestions of this paper are about stone milling, which is the least investigated machining method in the world.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

scholarly journals Deep Learning Approach for Vibration Signals Applications

Sensors ◽  
2021 ◽  
Vol 21 (11) ◽  
pp. 3929
Author(s):  
Han-Yun Chen ◽  
Ching-Hung Lee
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Parameters Optimization ◽  
Frequency Spectra ◽  
Vibration Signals ◽  
Bearing Faults ◽  
Time Frequency ◽  
And Performance ◽  
The One ◽  
Short Time

This study discusses convolutional neural networks (CNNs) for vibration signals analysis, including applications in machining surface roughness estimation, bearing faults diagnosis, and tool wear detection. The one-dimensional CNNs (1DCNN) and two-dimensional CNNs (2DCNN) are applied for regression and classification applications using different types of inputs, e.g., raw signals, and time-frequency spectra images by short time Fourier transform. In the application of regression and the estimation of machining surface roughness, the 1DCNN is utilized and the corresponding CNN structure (hyper parameters) optimization is proposed by using uniform experimental design (UED), neural network, multiple regression, and particle swarm optimization. It demonstrates the effectiveness of the proposed approach to obtain a structure with better performance. In applications of classification, bearing faults and tool wear classification are carried out by vibration signals analysis and CNN. Finally, the experimental results are shown to demonstrate the effectiveness and performance of our approach.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

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