scholarly journals Study on Technological Effects of a Precise Grooving of AlSi13MgCuNi Alloy with a Novel WCCo/PCD (DDCC) Inserts

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2467 ◽  
Author(s):  
Szymon Wojciechowski ◽  
Rafał Talar ◽  
Paweł Zawadzki ◽  
Stanisław Legutko ◽  
Radosław Maruda ◽  
...  
Keyword(s):  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Fold Increase ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Machined Surface ◽  
Cutting Path

The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.

Experimental Study on Nano-TiAlN Coated Carbide Tools in Turning Austenitic Stainless Steel

2012 ◽  
Vol 723 ◽  
pp. 247-251
Author(s):  
Hai Dong Yang ◽  
Zhi Ding
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Dry Cutting ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Austenitic stainless steel has poor cutting performance, especially when the inappropriate choice of tool materials and cutting parameters, cutting tool life will be shortened and the quality of machined surface is poor. In this paper, 0Cr18Ni9 stainless steel dry cutting tests had been done with nano-TiAlN coated carbide blade YGB202, the relationship between tool life and cutting speed, tool wear mechanism had been analyzed. In order to improve the processing efficiency and tool life, process parameters were optimized.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

Effects of Process Parameters on Surface Quality in Turning of Mild Steel with Rotary Cutting Tool

2012 ◽  
Vol 445 ◽  
pp. 137-142 ◽  
Author(s):  
Murat Kiyak ◽  
Erhan Altan
Keyword(s):  
Mild Steel ◽  
Tool Life ◽  
Contact Region ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Negative Effects ◽  
Machining Processes ◽  
Machined Surface ◽  
Inclination Angles ◽  
Rotary Cutting

In machining processes, great amount of the cutting energy transforms to heat energy. Tool life decreases and the quality of the machined surface changes by the effects of heat during machining. Many researches are being done on the reduction of the negative effects of the heat on the tool. In this respect, cutting fluids are used, but usages of them are limited because of their some harmfully effects to the environment. In order to reduce the tool wear and to use the tool longer, during cutting continuously variation of the contact region of the tool and the chip can been realized by using self-propelled rotary tools. The tool life is longer in rotary tools when compared with stationary cutting tools. In machining with these tools lower heat effect at the cutting edge is observed. In this study, the effects of cutting parameters on surface roughness of machined part has been investigated during the turning of mild steel using self-propelled rotary tools. In experiments, cutting tools which inclination angles were 20°, 30° and 45° and rake angles were 0° and-5° were used. Cutting speeds were taken as 60 m/min and 120m/min. RCMX insert with 32mm diameter was used. Feed were chosen as 0.1, 0.2 and 0.4 mm/rev and cutting depth was set at 0.25 mm.

Experimental Research on Cutting Temperature of Cemented Carbide Tools during Cutting Austenitic Manganese Steel

2011 ◽  
Vol 413 ◽  
pp. 347-350
Author(s):  
Gui Quan Han ◽  
Zeng Zhi Zhang
Keyword(s):  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Manganese Steel ◽  
Dry Cutting ◽  
Austenitic Manganese Steel ◽  
Austenitic Manganese ◽  
Cemented Carbide Tools

The cutting temperature rules of cemented carbide tools YW2 during cutting austenitic manganese steel ZGMn13 were investigated by experiments through systematically changing cutting parameters (cutting speed, feed, cutting depth) under the condition of dry cutting. The experiential expressions for cutting temperature of tools were summarized while dominating factors for influencing cutting temperature were analyzed. The results show that accounting values by experiential formulae basically match actually measuring values by experiments which may play an important role in studying cutting law of austenitic manganese steel. Cutting speed plays a major role in determining the temperature of cutting tools, followed by feed rate and depth of cutting.

scholarly journals Study on the Cutting Performance of Micro Textured Tools on Cutting Ti-6Al-4V Titanium Alloy

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 137 ◽  
Author(s):  
Kairui Zheng ◽  
Fazhan Yang ◽  
Na Zhang ◽  
Qingyu Liu ◽  
Fulin Jiang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Feed Force ◽  
Cemented Carbide Tools

Titanium alloys are widely used in various fields, but their machinability is poor because the chip would easily adhere to the tool surface during cutting, causing poor surface quality and tool wear. To improve the cutting performance of titanium alloy Ti-6Al-4V, experiments were conducted to investigate the effect of micro textured tool on the cutting performances. The cemented carbide tools whose rake faces were machined with line, rhombic, and sinusoidal groove textures with 10% area occupancy rates were adopted as the cutting tools. The effects of cutting depth and cutting speed on feed force and main cutting force were discussed based on experimental results. The results show that the cutting force produced by textured tools is less than that produced by non-textured tools. Under different cutting parameters, the best cutting performance can be obtained by using sinusoidal textured tools among the four types of tools. The wear of micro textured tools is significantly lower than that of non-textured tools, due to a continuous lubrication film between the chip and the rake face of the tool that can be produced because the micro texture can store and replenish lubricant. The surface roughness obtained using the textured tool is better than that using the non-textured tool. The surface roughness Ra can be reduced by 35.89% when using sinusoidal textured tools. This study is helpful for further improving the cutting performance of cemented carbide tools on titanium alloy and prolonging tool life.

scholarly journals Machining of Aluminums Alloys with the Addition of Reinforced Carbide Phase

2020 ◽  
Vol 60 (1) ◽  
pp. 11-20
Author(s):  
Piotr Putyra ◽  
Marcin Podsiadło ◽  
Lucyna Jaworska ◽  
Jolanta Laszkiewicz-Łukasik ◽  
Maciej Dyzia ◽  
...  
Keyword(s):  
Volume Fraction ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Ceramic Phase ◽  
The Matrix ◽  
Longitudinal Turning

This paper presents the results of the processes of treating aluminum matrix casting materials with the addition of a ceramic phase. The matrix of the composite material was an Al-Si7 casting alloy with addition of 2 mass% Mg. The volume fraction of the reinforcing phase in the form of silicon carbide ranged from 5 to 15 vol.%. Preliminary machining tests were carried out at the Mori Seiki NL2000SY turning and milling center. The cutting properties were evaluated during longitudinal turning. Cutting tests were carried out using tools made of polycrystalline diamond, regular boron nitride, and cemented carbides. The nature of VBB wear was checked in accordance with PN-ISO 3685:1996. The influence of machining parameters (cutting speed, feed, cutting depth) on the value of cutting tools temperature was determined. An analysis of the chip shaping mechanism during machining was performed at various cutting parameters. The tests were carried out using the FLIR A655 thermal imaging camera and the fast Phantom MIRO M310 fast camera. Cast composite materials were also subjected to the processes of waterjet cutting, EDM cutting, and EDM drilling (EDM electro discharge machining).

scholarly journals Surface Layer States of Worn Uncoated and TiN-Coated WC/Co-Cemented Carbide Cutting Tools after Dry Plain Turning of Carbon Steel

2013 ◽  
Vol 2013 ◽  
pp. 1-10 ◽  
Author(s):  
Johannes Kümmel ◽  
Katja Poser ◽  
Frederik Zanger ◽  
Jürgen Michna ◽  
Volker Schulze
Keyword(s):  
Surface Layer ◽  
Tool Wear ◽  
Tool Life ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cemented Carbide ◽  
Machining Parameters ◽  
Surface Layers ◽  
Cutting Inserts ◽  
1045 Steel

Analyzing wear mechanisms and developments of surface layers in WC/Co-cemented carbide cutting inserts is of great importance for metal-cutting manufacturing. By knowing relevant processes within the surface layers of cutting tools during machining the choice of machining parameters can be influenced to get less wear and high tool life of the cutting tool. Tool wear obviously influences tool life and surface integrity of the workpiece (residual stresses, surface quality, work hardening, etc.), so the choice of optimised process parameters is of great relevance. Vapour-deposited coatings on WC/Co-cemented carbide cutting inserts are known to improve machining performance and tool life, but the mechanisms behind these improvements are not fully understood. The interaction between commercial TiN-coated and uncoated WC/Co-cemented carbide cutting inserts and a normalised SAE 1045 steel workpiece was investigated during a dry plain turning operation with constant material removal under varied machining parameters. Tool wear was assessed by light-optical microscopy, scanning electron microscopy (SEM), and EDX analysis. The state of surface layer was investigated by metallographic sectioning. Microstructural changes and material transfer due to tribological processes in the cutting zone were examined by SEM and EDX analyses.

scholarly journals Wear Analysis of Cemented Carbide during Turning of Cast Iron Considering Economical Machining Speed

2017 ◽  
Vol 37 (1) ◽  
pp. 27-34
Author(s):  
Natalia Znojkiewicz ◽  
Dariusz Korzeniewski ◽  
Martyna Wiciak
Keyword(s):  
Cast Iron ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Angular Speed ◽  
Cemented Carbide ◽  
Literature Analysis ◽  
Piston Rings ◽  
Wear Analysis ◽  
Machining Speed

Abstract The purpose of this paper is to find economical machining speed during turning of grooves for piston rings with various feeds. In the first part of the paper, literature analysis concerning durability of cutting tools is presented. Next, the wear of cemented carbide cutting tools during turning of cast iron is researched. The research has been done for seven cutting tools. During conducted turning trials, angular speed has been altered from n=530rev/min to n=710rev/min and feeds from f=0.007mm/rev to f=0.105mm/rev. On the basis of Taylor’s equation, which relates cutting speed to tool life, the economical cutting speed is established with the application of two various methods.

Towards High Productive Roughing of Profiled Grooves in Nickel Based Alloys

2016 ◽  
Author(s):  
F. Klocke ◽  
B. Doebbeler ◽  
M. Seimann ◽  
M. Binder
Keyword(s):  
Cutting Tools ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Cemented Carbide ◽  
Oxide Ceramic ◽  
Machining Parameters ◽  
Machining Processes ◽  
Side Milling ◽  
Cutting Speeds ◽  
Hot Hardness

Facing a high demand for aircraft engines over the next decades in combination with new challenging materials, aircraft engine manufacturers are striving for new manufacturing processes. The manufacturing of profiled grooves for the mounting of the turbine blades on the disc is a bottle neck process today due to the exclusive use of High Speed Steel (HSS) tools in broaching. Because of the limited hot hardness of HSS, the applied cutting speeds are low compared to other conventional machining processes, i.e. 2–5 m/min. Furthermore, the broaching process has some more drawbacks regarding flexibility, capital commitment for machinery and tools as well as costs. Nevertheless, broaching offers outstanding properties regarding surface finish, manufacturing accuracy and is still a productive process due to the many cutting edges applied. There are some alternative process chains which are not yet in industrial use, which are able to substitute and/or complement the HSS-broaching process. In this paper, results are presented on two different roughing strategies for the manufacturing of profiled grooves in Nickel Based Alloys Allvac718plus and Inconel718. On the one hand, rough broaching with cemented carbide tools using indexable inserts was investigated at different cutting speeds, which are up to five times higher than the applied cutting speeds in industrial applications with HSS-tools. Two different carbide grades were investigated varying the cobalt content and the grain size. Cemented carbide is not state of the art in broaching Nickel Based Alloys due to its low fracture toughness. Different cutting edge inclination angles were applied and their effect on cutting forces, wear and tool chipping tendency were analyzed. On the other hand, rough side milling with ceramic cutting tools was investigated. Ceramic cutting tools excel in high hot hardness and thus can be used at very high cutting speeds i.e. up to 1000 m/min in Nickel Based Alloys. However, being very brittle and sensitive to alternating loads and thermal shock, machining processes with ceramic tools require extensive process design. In side milling experiments, Whisker reinforced as well as SiAlON and Oxide ceramic were investigated. In a first step, a window for machining parameters was identified. Then, tool life tests were conducted varying the feed at a fixed cutting speed of 1000 m/min. Subsequent to the experiments, the rim zone of the roughed grooves was investigated depending on the wear state of the used tools. The condition of the rim zone is a major criterion for the assessment of the adequacy of the roughing processes, because it can affect the subsequent finishing process. In further work, the interdependencies between the investigated roughing processes and finishing will be addressed.

scholarly journals Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

2019 ◽  
Vol 9 (2) ◽  
pp. 109-113
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Aluminum Alloy 7075

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.

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