scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

scholarly journals An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4427
Author(s):  
Antoni Świć ◽  
Arkadiusz Gola ◽  
Olga Orynycz ◽  
Karol Tucki
Keyword(s):  
Control System ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Contact Heating ◽  
Thin Walled ◽  
Micro Machine

Low-rigidity thin-walled parts are components of many machines and devices, including high precision electric micro-machines used in control and tracking systems. Unfortunately, traditional machining methods used for machining such types of parts cause a significant reduction in efficiency and in many cases do not allow obtaining the required accuracy parameters. Moreover, they also fail to meet modern automation requirements and are uneconomical and inefficient. Therefore, the aim of provided studies was to investigate the dependency of cutting forces on cutting parameters and flank wear, as well as changes in cutting forces induced by changes in heating current density and machining parameters during the turning of thin-walled parts. The tests were carried out on a specially designed and constructed turning test stand for measuring cutting forces and temperature at specific cutting speed, feed rate, and depth of cut values. As part of the experiments, the effect of cutting parameters and flank wear on cutting forces, and the effect of heating current density and turning parameters on changes in cutting forces were analyzed. Moreover, the effect of cutting parameters (depth of cut, feed rate, and cutting speed) on temperature has been determined. Additionally, a system for controlling electro-contact heating and investigated the relationship between changes in cutting forces and machining time in the operations of turning micro-machine casings with and without the use of the control system was developed. The obtained results show that the application of an electro-contact heating control system allows to machine conical parts and semi-finished products at lower cutting forces and it leads to an increase in the deformation of the thin-walled casings caused by runout of the workpiece.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

scholarly journals Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3974 ◽  
Author(s):  
Mohamed Shnfir ◽  
Oluwole A. Olufayo ◽  
Walid Jomaa ◽  
Victor Songmene
Keyword(s):  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Mechanical Shock ◽  
Tool Edge ◽  
Aisi 1045 ◽  
High Feed ◽  
1045 Steel ◽  
Edge Preparation

Intermittent machining using ceramic tools such as hard milling is a challenging task due to the severe mechanical shock that the inserts undergo during machining and the brittleness of ceramic inserts. This study investigates the machinability of hardened steel AISI 1045 during face milling using SiAlON and whisker (SiCW) based ceramic inserts. The main focus seeks to identify the effects of cutting parameters, milling configuration, edge preparation and work material hardness on machinability indicators such as resultant cutting force, power consumption and flank tool wear. The effects of these varying cutting conditions on performance characteristics were investigated using a Taguchi orthogonal array design L32 (21 44) and evaluated using ANOVA. Results indicate lower resultant cutting forces were recorded with honed edge inserts of SiAlON ceramic grade. In addition, a decrease in resultant cutting forces was associated with reduced feed rates and increased hardness. The feed rate and cutting speed were also identified as the greatest influencing factors in the amount of cutting power. The main wear mechanisms responsible for flank wear on the ceramic inserts are micro-scale abrasion and micro-chipping. Increased flank wear was observed at low cutting speed and high feed rates, while micro-chipping mostly ensued from the cyclic loading of the radial tool edge form, which is more susceptible to impact fragmentation. Thus, the use of tools with chamfered tool-edge preparation greatly improved observed wear values. Additional confirmation tests were also conducted to validate the results of the tests.

scholarly journals System for Tool-Wear Condition Monitoring in CNC Machines under Variations of Cutting Parameter Based on Fusion Stray Flux-Current Processing

Sensors ◽  
2021 ◽  
Vol 21 (24) ◽  
pp. 8431
Author(s):  
Arturo Yosimar Jaen-Cuellar ◽  
Roque Alfredo Osornio-Ríos ◽  
Miguel Trejo-Hernández ◽  
Israel Zamudio-Ramírez ◽  
Geovanni Díaz-Saldaña ◽  
...  
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Economic Benefits ◽  
Numerical Control ◽  
Cnc Machines ◽  
Cutting Tool Wear

The computer numerical control (CNC) machine has recently taken a fundamental role in the manufacturing industry, which is essential for the economic development of many countries. Current high quality production standards, along with the requirement for maximum economic benefits, demand the use of tool condition monitoring (TCM) systems able to monitor and diagnose cutting tool wear. Current TCM methodologies mainly rely on vibration signals, cutting force signals, and acoustic emission (AE) signals, which have the common drawback of requiring the installation of sensors near the working area, a factor that limits their application in practical terms. Moreover, as machining processes require the optimal tuning of cutting parameters, novel methodologies must be able to perform the diagnosis under a variety of cutting parameters. This paper proposes a novel non-invasive method capable of automatically diagnosing cutting tool wear in CNC machines under the variation of cutting speed and feed rate cutting parameters. The proposal relies on the sensor information fusion of spindle-motor stray flux and current signals by means of statistical and non-statistical time-domain parameters, which are then reduced by means of a linear discriminant analysis (LDA); a feed-forward neural network is then used to automatically classify the level of wear on the cutting tool. The proposal is validated with a Fanuc Oi mate Computer Numeric Control (CNC) turning machine for three different cutting tool wear levels and different cutting speed and feed rate values.

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.

Hard Turning of Hot Work Steel X38CRMOV5-3: Evaluation of Surface Roughness and Current Values Using Cutting Parameters

2020 ◽  
Author(s):  
Ali Kemal Cakir
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Feed Rate ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Dry Machining ◽  
Motor Current ◽  
Design Factors

This study evaluates the surface roughness and current values using cutting parameters in the turning of AISI H11 being hot work tool steel under dry machining conditions. The selected design factors are the depth of cut, feed rate, cutting speed. A design of experiments was used to carry out this research. The obtained results were analyzed to determine the effects of input parameters on the resultant surface roughness, current using the analysis of variance (ANOVA) and the Response Surface Methodology (RSM). The experimental results showed that increasing feed rate increased the surface roughness, and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate on the surface roughness. Also, the motor current values were influenced by the 38,48% depth of cut, 23,98% cutting speed, 25,52% feed rate, respectively.

Micro-Milling of Hardened AISI D2 Tool Steel

2012 ◽  
Vol 445 ◽  
pp. 62-67 ◽  
Author(s):  
J.B. Saedon ◽  
S.L. Soo ◽  
D.K. Aspinwall ◽  
A. Barnacle
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Operating Conditions ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Aisi D2

The paper presents an experimental investigation into the slotting of hardened AISI D2 (~62HRC) tool steel using 0.5mm diameter coated (TiAlN) tungsten carbide (WC) end mills. SEM analysis of tool morphology and coating integrity was undertaken on all tools prior to testing. Tool wear details are given based on resulting cutter diameter and slot width reduction. In addition, cutting forces are also presented together with details of workpiece burr formation. A full factorial experimental design was used with variation of cutting speed, feed rate and depth of cut, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on microscale milling best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors. Cutting speed was shown to have the greatest effect on tool wear (33% PCR). When operating at 50m/min cutting speed with a feed rate of 8µm/rev and a depth of cut of 55µm, cutter diameter showed a reduction of up to 82µm for a 520mm cut length. SEM micrographs of tool wear highlighted chipping / fracture as the primary wear mode with adhered workpiece material causing further attritious wear when machining was continued up to 2.6m cut length. All tests produced burrs on the top edges of the slots which varied in size / width to a lesser or greater degree. Under the most severe operating conditions, burr width varied from approximately 50µm to more than 220µm over the 520mm cut length. Cutting forces in general were less than 12N up to test cessation.

scholarly journals Impact of Cutting Forces and Chip Microstructure in High Speed Machining of Carbon Fiber – Epoxy Composite Tube

2017 ◽  
Vol 62 (3) ◽  
pp. 1771-1777 ◽  
Author(s):  
Y. Allwin Roy ◽  
K. Gobivel ◽  
K.S. Vijay Sekar ◽  
S. Suresh Kumar
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
High Speed Machining ◽  
The Impact ◽  
Thrust Forces

AbstractCarbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure which offer vital inputs to the machinability and deformation characteristics of the material. In this work, the orthogonal machining of CFRP was conducted by varying the cutting parameters such as cutting speed and feed rate at high cutting speed/feed rate ranges up to 346 m/min/ 0.446 mm/rev. The impact of the cutting parameters on cutting forces (principal cutting, feed and thrust forces) and chip microstructure were analyzed. A significant impact on thrust forces and chip segmentation pattern was seen at higher feed rates and low cutting speeds.

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