scholarly journals Wear Characteristics of Cutting Tool in Brittle Removal of a Ductile Meta in High-Speed Machining

Symmetry ◽  
2021 ◽  
Vol 13 (9) ◽  
pp. 1679
Author(s):  
Guosheng Su ◽  
Yuhao Wang ◽  
Zhitao Han ◽  
Peirong Zhang ◽  
Hongxia Zhang ◽  
...  
Keyword(s):  
Tool Wear ◽  
Pure Iron ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Rake Face ◽  
Workpiece Material ◽  
Wear Characteristics ◽  
Ductile Metal ◽  
Cutting Speeds

The contact stress and heating effect between the cutting tool and workpiece in metal machining is symmetrical. However, the symmetry may be destroyed by changes in the workpiece material mechanical properties, such as ductility. The goal of this study is to reveal the wear characteristics of the cutting tool in machining a ductile metal with the cutting speed at which the metal is embrittled by the high-strain-rate-embrittle effect (HSREE). Orthogonal high-speed turning experiments were carried out. Pure iron type DT8 was cut at different cutting speeds, ranging from 1000 m/min to 9000 m/min. The shape and morphology of the chips obtained in the experiment were observed and analyzed by optical microscope and scanning electron microscope (SEM). Tool wear characteristics at different cutting speeds were observed. It shows that the pure iron becomes completely brittle when the cutting speed is higher than 8000 m/min. On the rake face, the coating of the cutting tool bursts apart and peels off. A matrix crack originates in the cutting edge or rake face and extends to the flank face of the cutting tool. The effects of HSREE on the tool wear is discussed. The findings of this study are helpful for choosing a suitable tool for brittle cutting of the ductile metal pure iron with very high cutting speed and solving the problems in machining due to its high ductility and high stickiness.

scholarly journals Wear and MnS Layer Adhesion in Uncoated Cutting Tools When Dry and Wet Turning Free-Cutting Steels

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 556 ◽  
Author(s):  
D. Martinez Krahmer ◽  
S. Hameed ◽  
A. J. Sánchez Egea ◽  
D. Pérez ◽  
J. Canales ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Wear Behavior ◽  
Manganese Sulfide ◽  
Cutting Speed ◽  
Hard Metal ◽  
Rake Face ◽  
Machined Surface ◽  
Eds Analysis ◽  
Cutting Speeds

Free-cutting steels are developed to produce large quantities of parts with low mechanical behavior, mainly for automotive sector. These alloys contain phosphorous, lead, sulfur, and manganese that help to improve the machinability and surface roughness. However, due to the toxicity of lead, steel mills in recent years have been focusing on non-toxic steels to produce minimum environmental pollution and better machinability. The present work investigates the tool wear during dry and wet turning of free-cutting steels (SAE 1212, SAE 12L14, and SAE 1215) by using uncoated hard metal inserts at three cutting speeds. Additionally, a EDS analysis was performed to determine the presence of Mn and S elements at the rake face of the cutting tool that can induce a higher adhesion of manganese sulfide (MnS). The results show that the SAE 12L14 steel has the best performance in terms of tool life at different cutting speeds. This difference is maximum at the lowest cutting speed, which gradually decreases with the increase of the cutting speed. The wear behavior is evaluated in the three steel alloys at each cutting speed and, consequently, the tool wear exhibits a slightly better performance in the dry machining condition for higher cutting speeds (180 and 240 m/min), independent of the steel alloy. Finally, EDS analysis confirms the presence of Mn and S elements at the rake face of the inserts machined in dry condition. Hence, MnS is expected to interpose between the machined surface and cutting tool surface to behave similar to tribofilm by reducing the wear on the cutting edge.

Feasibility Study of the Effectiveness of Cryogenically Treated Ceramic Inserts for Pocket Milling Maneuvers

2009 ◽  
Author(s):  
Justin L. Milner ◽  
Jeffrey A. Beers ◽  
John T. Roth
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Feasibility Study ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Initial Study ◽  
Machining Processes ◽  
Cutting Speeds

Machining is a popular and versatile manufacturing process that is widely used in today’s industry when producing metallic parts; however, limited tool life can make this an expensive and time consuming fabrication technique. Consequently, methods that decrease the rate of tool wear and, thus, increase tool longevity are a vital component when improving the efficiency of machining processes. To this end, cryogenically treating cutting tools (especially high-speed steel tooling) is becoming more commonplace since research has shown that the treated tooling exhibits significantly higher wear resistance. At this point, however, the effect of cryogenic treatments on ceramic tooling has not been established. Considering this, the research herein presents a feasibility study on the effectiveness of using cryogenic treatments to enhance the wear resistance of WG-300 whisker-reinforced ceramic cutting inserts. To begin, the effect of the cryogenic treatment on the insert’s hardness is examined. Subsequently, tool wear tests are conducted at various cutting speeds. Through this study, it is shown that cryogenically treating the ceramic inserts decreases the rate of tool wear at each of the cutting speeds that were tested. However, the degree of wear resistance introduced by cryogenically treating the inserts proved to be highly dependent on the cutting speed, with slower speeds exhibiting greater improvements. Thus, based on this initial study, the cryogenic treatment of ceramic tooling appears to produce beneficial results, potentially increasing the overall efficiency of machining processes.

High Speed Machining: A Review from a Viewpoint of Chip Formation

2011 ◽  
Vol 188 ◽  
pp. 578-583 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Masahiro Anzai ◽  
Tsuneo Egawa ◽  
Norihiko Narutaki ◽  
Kazuhiro Shintani ◽  
...  
Keyword(s):  
Tool Wear ◽  
Life Span ◽  
High Speed ◽  
Cutting Speed ◽  
Strong Nonlinearity ◽  
High Speed Machining ◽  
Cast Irons ◽  
Sliding Test ◽  
Cutting Experiments ◽  
Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

Influence of Cutting Parameters and Tool Wear on Martensitic Stainless Steel Surface Integrity After a Face Milling Process

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Surface Integrity ◽  
Surface Finish ◽  
Cutting Tool ◽  
Fatigue Behavior ◽  
Cutting Speed ◽  
Stainless Steel Surface ◽  
Workpiece Material

Surface finish is one of the most relevant aspects of machining operations, since it is one of the principle methods to assess quality. Also, surface finish influences mechanical properties such as fatigue behavior, wear, corrosion, etc. The feed, the cutting speed, the cutting tool material, the workpiece material and the cutting tool wear are some of the most important factors that affects the surface roughness of the machined surface. Due to the importance of the martensitic 416 stainless steel in the petroleum industry, especially in valve parts and pump shafts, this material was selected to study the influence of the feed per tooth and cutting speed on tool wear and surface integrity. Also the influence of tool wear on surface roughness is analyzed. Results showed that high values of roughness are obtained when using low cutting speed and feed per tooth and by using these conditions tool wear decreases prolonging tool life.

Experiments on High-Speed and Dry Cutting with PCBN Tool

2010 ◽  
Vol 431-432 ◽  
pp. 114-117
Author(s):  
Hai Dong Yang ◽  
Zhen Hua Qing ◽  
Feng Xie ◽  
Chong Gao Zhang
Keyword(s):  
Tool Wear ◽  
Alloy Steel ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Mechanism ◽  
Dry Cutting ◽  
Pcbn Tool ◽  
Workpiece Temperature ◽  
Hardened Alloy ◽  
Cutting Speeds

This paper deals with the High-speed Hard and Dry Cutting mechanism of hardened alloy-steel with PCBN tool: the cutting speed and workpieces temperature and tool wear are being discussed in different cutting speeds when cutting alloy-steel 42CrMo. After the workpiece temperature measured by ThermaVision, it is proved that the workpiece temperature was not high and changed little. Through the SEM and EDS analyses for chip and tool wear, it is proved that PCBN tool is suitable for High-speed Hard and Dry Cutting. It is suitable for PCBN tool to cut hardened alloy-steel 42CrMo instead of grinding.

Simulation of Fully Sintering Dental Zirconia Milling Process Based on Discrete Element Method

2013 ◽  
Vol 568 ◽  
pp. 49-54
Author(s):  
H.B. Wu ◽  
Q.P. Sun ◽  
Dun Wen Zuo
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Element Model ◽  
Discrete Element ◽  
Milling Process ◽  
Discrete Element Model ◽  
Surface Cracks ◽  
Coating Technology ◽  
Cutting Speeds

Discrete element model of fully sintering dental zirconia was constructed and calibrated. Based on the model, the dynamic process of low-speed milling of zirconia was simulated, and the effects of different cutting speeds, cutting widths and federates on the formation of surface cracks were also analyzed. Results show that residue cracks number and maximum depth increases significantly with increase of the cutting width, while the influence of cutting speed and federates is not distinct. That shows the possibility of high-speed machining on fully sintering dental zirconia with development of coating technology of cutting tool.

Evidence of Phase Dependent Tool Wear in Ti-6Al-4V Turning Experiments Using PCD and Carbide Inserts

2012 ◽  
Author(s):  
David J. Schrock ◽  
Patrick Kwon
Keyword(s):  
Phase Transformation ◽  
Tool Wear ◽  
Cutting Speed ◽  
Laser Scanning Microscopy ◽  
Confocal Laser ◽  
Rake Face ◽  
Work Material ◽  
Significant Difference ◽  
Pcd Tools ◽  
Cutting Speeds

This paper presents evidence of phase transformation in turning titanium work material and discusses its impact on tool wear. Tool wear of polycrystalline diamond inserts was studied in turning experiments on Ti-6Al-4V. Confocal laser scanning microscopy was conducted to analyze the rake face of the turning inserts. At cutting speeds of 61m/min, the rake face exhibited scalloped-shaped, fractured, uneven, and rough wear. This is characteristic of attrition wear. At cutting speeds of 122m/min, wear was smooth and even in nature, which is a typical characteristic of diffusion/dissolution wear. At a cutting speed of 91m/min, the wear was a combination of those observed at speeds of 61m/m and 122m/m. A comparison of the wear on the PCD tools to that of WC-6Co from earlier work is also discussed. A significant difference in wear existed between the two different cutting tool materials at the low cutting speed. This difference in wear was linked to a transition from alpha to beta phase in the titanium work material. Temperature estimates on the rake face of the tool previously extracted from FEM support the possibility of phase transformation at the cutting data tested.

scholarly journals Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

2016 ◽  
Vol 2016 ◽  
pp. 1-10 ◽  
Author(s):  
Manikandakumar Shunmugavel ◽  
Ashwin Polishetty ◽  
Junior Nomani ◽  
Moshe Goldberg ◽  
Guy Littlefair
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Flank Wear ◽  
Research Work ◽  
Cutting Speed ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
All Speeds ◽  
Cutting Speeds

This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

Effect of Boronizing on Cutting Performance of Ti(C,N)-Based Cermet Tool

2013 ◽  
Vol 589-590 ◽  
pp. 390-394
Author(s):  
Hai Dong Yang ◽  
Ju Li Hu ◽  
Yu Ming Zou ◽  
Xiao Yang ◽  
Xiao Jun Liu
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Great Influence ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Test Results ◽  
Negative Effects ◽  
High Speed Cutting ◽  
Ceramic Cutting Tool ◽  
Cutting Speeds

Through the experiment of cutting 45 steel, the influence of boronizing on Ti (C,N)-based ceramic cutting performance in different cutting speeds were discussed. The test results indicated that: regardless of boriding, cutting speed has a great influence on the life of Ti (C,N)-based ceramic cutting tool. Within the limit of 200~400 m/min, the lower the cutting speed is, the longer tools life. At the minimum speed, boronizing greatly improves cutting performance and doubles tool life. It has no significant but negative effects once over 300 m/min. The decrease of the abrasion resistance of boronized layer is mainly influenced by the intense thermal shock of high speed cutting.

Performance of carbide tools in high-speed dry turning iron-based superalloys

2021 ◽  
pp. 095440542110285
Author(s):  
Xianhua Tian ◽  
Kuicheng Yan ◽  
Zhi Wang ◽  
Fangwei Xie ◽  
Ya Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Surface Finish ◽  
High Speed ◽  
Cutting Speed ◽  
Rake Face ◽  
Dry Turning ◽  
Coated Tools ◽  
Flank Face ◽  
Iron Based ◽  
Cutting Speeds

Machining quality and productivity of superalloys are limited due to their poor machinability, and fewer studies have focused on the cutting of iron-based superalloys. In this study, the cutting performance of coated and uncoated carbide tools in high-speed dry turning iron-based superalloy GH2132 was investigated by performing a series of cutting experiments. The experimental results indicated that cutting temperature and cutting forces increased, while tool life decreased with the increase in the cutting speed from 30 to 100 m/min. Under relatively low cutting speeds, flank face wear was dominated by abrasion and adhesion, while rake face wear mainly involved built-up edge (BUE), built-up layer (BUL), adhesion, and breakage near the depth of cut. Under higher cutting speed, adhesion wear was more serious on the flank face, and peeling off of the coatings and substrate occurred on the rake face. Owing to the protective effect of (Ti, Al)N + TiN coating, the coated tools exhibited better wear resistance and thus longer tool life, in particular, under higher cutting speeds. Analysis of the tool wear gap in the horizontal direction indicates that better dimensional accuracy could be obtained when coated tools are used. In dry turning of GH2132 with carbide tools, a favorable surface finish could be obtained. The surface roughness roughly showed a tendency to first decrease and then increase with the increase in average flank wear. The coated tools should be avoided to machine GH2132 at higher cutting speed due to the poor surface finish.

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