scholarly journals Influence of Water-Miscible Cutting Fluids on Tool Wear Behavior of Different Coated HSS Tools in Hobbing

2018 ◽  
Vol 8 (2) ◽  
pp. 10 ◽  
Author(s):  
Hironori Matsuoka ◽  
Akio Kubo ◽  
Hajime Ono ◽  
Takahiro Ryu ◽  
Hua Qiu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Flank Wear ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Crater Wear ◽  
Coated Tools ◽  
Finished Surface ◽  
Influence Of Water ◽  
Tool Cutting

The present paper describes the influence of water-miscible cutting fluids on tool life (flank wear) and crater wear of various coated cutting tools and finished surface roughness, as compared with the cases of dry cutting and wet cutting using cutting oil in hobbing in an attempt to improve the working environment. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The following results were obtained. (1) In the case of an uncoated tool, cutting oil was more effective than dry cutting in reducing flank wear. Cutting oil and water-miscible cutting fluids were more effective in reducing flank wear than dry cutting using TiN- and TiAlN-coated tools. The use of water-miscible cutting fluids in conjunction with TiSiN- and AlCrSiN-coated tools prolongs tool life. (2) For all coated tools, the use of cutting oil or water-miscible cutting fluids were effective in reducing crater wear. Especially, water-miscible cutting fluids were effective for TiSiN- and AlCrSiN-coated tools. (3) Regarding the finished surface roughness, in the case of dry cutting, the finished surface roughness was similar for various types of coating films. When using cutting oil or a water-miscible cutting fluid, the finished surface roughness improved compared with dry cutting, independent of the type of coating film applied. The finished surface roughness obtained using water-miscible cutting fluid was approximately the same as or smaller than that obtained using cutting oil. (4) With respect to flank wear, crater wear, and finished surface roughness, the water-miscible cutting fluid of emulsion type containing a large amount of synthetic lubricating additives was suitable for the AlCrSiN-coated tool.

Fundamental Research on Hobbing and Finish-Hobbing in Dry and with MQL System

2017 ◽  
Vol 740 ◽  
pp. 139-144 ◽  
Author(s):  
Yuta Sato ◽  
Hironori Matsuoka ◽  
Takahiro Ryu ◽  
Takashi Nakae ◽  
Akio Kubo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Flank Wear ◽  
Dry Cutting ◽  
Coated Tools ◽  
Coated Tool ◽  
Finished Surface ◽  
Fundamental Research ◽  
Minimal Quantity ◽  
Tool Cutting ◽  
Mql System

This paper deals with hobbing and finish-hobbing that considers the machine environment when using various hard hob materials. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The results are summarized as follows. (1) Under the condition of hobbing with TiN-coated tools in dry cutting and with a minimal quantity of lubricant (MQL) system, P20 and P30 hob materials as the substrate show stable cutting and do not cause tool failure. The flank wear obtained with P30 is less than that obtained with P10 and P20 in the case of the coated TiAlN film tool. The MQL system shows flank wear reduction compared with dry cutting. (2) Under the condition of finish-hobbing, when using the TiN-coated tool, the flank wear obtained with dry cutting is smaller than that obtained with the MQL system. The flank wear increases in the order of P10, P20 and P30 hob materials, and the P10 hob material is effective. The TiAlN-coated P30 tool decreases flank wear and is suitable for finish-hobbing in dry cutting and with the MQL system. (3) Under the condition of hobbing, the finished surface roughness obtained with the MQL system when using TiN-and TiAlN-coated tools is smaller than that obtained by dry cutting. (4) Under the condition of finish-hobbing, the finished surface roughness obtained with TiN-and TiAlN-coated P30 is small in dry cutting and with the MQL system.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Effects of Cutting Speed, Cutting Fluid, and Carbon Fiber Orientation on Cutting of CFRP during Turning

2017 ◽  
Vol 740 ◽  
pp. 133-138
Author(s):  
Ruito Anan ◽  
Hironori Matsuoka ◽  
Hajime Ono ◽  
Takahiro Ryu ◽  
Takashi Nakae ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Tool Wear ◽  
Fiber Orientation ◽  
Cutting Speed ◽  
Mineral Oil ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Reinforced Plastic ◽  
Finished Surface

This study examined the influence of cutting speed, cutting fluid, and pre-impregnated carbon fiber orientation on tool wear and finished surface roughness during turning of carbon fiber reinforced plastic (CFRP) pipes. In the dry cutting process, the tool wear decreased as the cutting speed was increased. An average cutting speed of 92 m/min or higher was found to be acceptable with respect to tool wear. The use of mineral oil resulted in a reduction of tool wear when compared with that in the case of dry cutting. The tool wear with water was lower than that with mineral oil. It was assumed that cooling by water was more effective than lubrication by mineral oil. The results clearly indicated that the tool wear and the finished surface roughness were affected by the carbon fiber orientation.

scholarly journals Experimental investigations of vibration and acoustics signals in milling process using kapok oil as cutting fluid

2020 ◽  
Vol 21 (5) ◽  
pp. 521
Author(s):  
Subramaniam Shankar ◽  
Murugasamy Manikandan ◽  
Gunasekaran Raja ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Sound Pressure ◽  
Flank Wear ◽  
Milling Process ◽  
Cutting Fluid ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Cutting Fluids

Vegetable oils are found as the feasible alternative for conventional minerals oils. There has been many environmental and health issues which are spotted with the use of conventional cutting fluids. There has been a great demand for developing new environmentally friendly vegetable based cutting fluids to reduce these harmful effects. In this present study, vegetable based kapok oil is used as a cutting fluid during milling to study its consequences over other conventional oils. The process parameters such as spindle speed, depth of cut and feed rate were optimized with respect to the flank wear (Vb) and surface roughness (Ra) respectively with the use of central composite design in response surface methodology (RSM). Further an attempt has been made to monitor the tool condition by measuring the cutting force, vibration and sound pressure simultaneously. Three different tool conditions such as dull, fresh and working were analyzed and their consequences were also reported. Also, the performance of the kapok oil is compared with the palm oil and mineral oil (SAE 20W 40). The feed rate has the major contribution for surface roughness and flank wear. It is found that the cutting force (F), sound pressure (p) and vibration (V) increases with the tool wear.

Performance of Synthetic and Mineral Soluble Oil When Turning AISI 8640 Steel

1997 ◽  
Vol 119 (4A) ◽  
pp. 580-586 ◽  
Author(s):  
A. R. Machado ◽  
M. F. Motta ◽  
M. B. da Silva
Keyword(s):  
Surface Roughness ◽  
Comparative Study ◽  
Tool Life ◽  
Cutting Forces ◽  
Flank Wear ◽  
Interface Temperature ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Steel Bars ◽  
Cemented Carbide Tools

The present work shows a comparative study of the application of synthetic and semi synthetic, mineral soluble oil (at concentrations of 3 and 10 percent) as well as dry cut when turning AISI 8640 steel bars with triple coated (TiC,Al2O3,TiN) P35 grade of cemented carbide tools. Tool lives, cutting forces, cutting temperatures and surface roughness were considered to evaluate the cutting fluids. Generally, the semi-synthetic gave longer tool life based on flank wear parameter VB. The surface roughness was not sensitive to the lubrication quality, if wear effects are not considered. Mean tool-chip interface temperature was lower with the synthetic fluid, followed by the semi-synthetic, mineral soluble oils and dry cutting, respectively. The inverse of this order was true for the cutting forces.

The Influence of the Lubrication Method and the Cutting Regime on the Surface Roughness when Milling 7175 Aluminum Alloy

2013 ◽  
Vol 371 ◽  
pp. 28-32 ◽  
Author(s):  
Vlad Diciuc ◽  
Mircea Lobonțiu ◽  
Gheorghe Bran ◽  
Vasile Lazar
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Feed Rate ◽  
Ecological Impact ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Lubrication Conditions

In the current paper, some aspects regarding the quality of the surface machined under different lubrication conditions is being assessed: cutting under a jet of cutting fluid, minimum quantity lubrication cutting, dry cutting. The objective was to assess the results obtained after MQL cutting in comparison with dry cutting and cutting under a jet of cutting fluid. The variables of the cutting regime were the feed rate and the type of milling (climb and conventional). This study has an important ecological impact over the use of cutting fluids.

scholarly journals A case study on the observability of cutting fluid flow and the associated contact mechanics in scaled rough surfaces

2021 ◽  
Vol 3 (5) ◽  
Author(s):  
Michael Müller ◽  
Lukas Stahl ◽  
Robar Arafat ◽  
Nadine Madanchi ◽  
Christoph Herrmann
Keyword(s):  
Fluid Flow ◽  
Contact Mechanics ◽  
Early Stage ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Friction Behavior ◽  
Two Fluids ◽  
Grinding Processes ◽  
Different Characteristics ◽  
Tool Cutting

AbstractIn grinding processes, heat is generated by the contact of the grains with the workpiece. In order to reduce damages on the workpiece and the grinding tool, cutting fluids are necessary for most grinding processes. They have the tasks of cooling and lubricating the contact zone and to remove the chips from the contact area. Different types of cutting fluids perform differently regarding these tasks, which can be investigated on a laboratory scale. However, the results of those experiments are limited to certain workpieces and processes and information about the contact mechanics are not available. The experimental investigation of contact mechanics under cutting fluid influence is hardly possible. For this reason, this paper uses a measurement strategy that uses scaled topographies and has already been successfully applied to contact mechanics problems. With such a setup, it is intended that at an early stage in the development of cutting fluids, their characteristics in terms of contact mechanics can be determined very efficiently. To demonstrate this approach, two different cutting fluids were tested with the help of the associated test rig—a water miscible emulsion and a non-water miscible grinding oil. The two fluids showed fundamentally different characteristics regarding their hydrodynamic load bearing effect, their influence on the friction behavior of the contact and their fluid flow in the gap. The properties analyzed here correspond to the practical application of cutting fluids. The results underline the potential of the presented setup for an integration into the development process of cutting fluids.

Effects of Cutting Condition on Surface Roughness when Turning Untreated and Sb-Treated Al-11%Si Alloys Using PVD Coated Tools

2013 ◽  
Vol 315 ◽  
pp. 413-417 ◽  
Author(s):  
Mohsen Marani Barzani ◽  
Mohd Yusof Noordin ◽  
Ali Akhavan Farid ◽  
Saaed Farahany ◽  
Ali Davoudinejad
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Manufacturing Processes ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Fabrication Cost ◽  
Coated Tools ◽  
Experimental Trials ◽  
Cutting Speeds

Surface roughness is an important output in different manufacturing processes. Its characteristic affects directly the performance of mechanical components and the fabrication cost. In this current work, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness in turning the untreated and Sb-treated Al-11%Si alloys. Experimental trials carried out using PVD TIN coated inserts. Experiments accomplished under oblique dry cutting when three different cutting speeds have been used at 70, 130 and 250 m/min with feed rates of 0.05, 0.1 and 0.15 mm/rev, whereas depth of cut kept constant at 0.05 mm. The results showed that Sb-treated Al-11%Si alloys have poor surface roughness in comparison to untreated Al-11%Si alloy. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Yunn-Shiuan Liao ◽  
Tsung-Hsien Li ◽  
Yi-Chen Liu
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Liquid Carbon ◽  
Dry Cutting ◽  
Machined Surface ◽  
Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

scholarly journals Analysis of Surface Roughness and Flank Wear Using the Taguchi Method in Milling of NiTi Shape Memory Alloy with Uncoated Tools

Coatings ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1259
Author(s):  
Emre Altas ◽  
Hasan Gokkaya ◽  
Meltem Altin Karatas ◽  
Dervis Ozkan
Keyword(s):  
Surface Roughness ◽  
Shape Memory Alloy ◽  
Shape Memory ◽  
Flank Wear ◽  
Cutting Tools ◽  
Dominant Factor ◽  
Niti Shape Memory Alloy ◽  
Machining Parameters ◽  
Nose Radius ◽  
Dry Cutting

The aim of this study was to optimize machining parameters to obtain the smallest average surface roughness (Ra) and flank wear (Vb) values as a result of the surface milling of a nickel-titanium (NiTi) shape memory alloy (SMA) with uncoated cutting tools with different nose radius (rε) under dry cutting conditions. Tungsten carbide cutting tools with different rε (0.4 mm and 0.8 mm) were used in milling operations. The milling process was performed as lateral/surface cutting at three different cutting speeds (Vc) (20, 35 and 50 m/min), feed rates (fz) (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The effects of machining parameters in milling experiments were investigated based on the Taguchi L18 (21 × 32) orthogonal sequence, and the data obtained were analyzed using the Minitab 17 software. To determine the effects of processing parameters on Ra and Vb, analysis of variance (ANOVA) was used. The analysis results reveal that the dominant factor affecting the Ra is the cutting tool rε, while the main factor affecting Vb is the fz. Since the predicted values and measured values are very close to each other, it can be said that optimization is correct according to the validation test results.

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