scholarly journals Analysis of the Performance of Drilling Operations for Improving Productivity

2021 ◽  
Author(s):  
Majid Tolouei-Rad ◽  
Muhammad Aamir
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Vital Role ◽  
Machining Process ◽  
Drilling Process ◽  
Single Shot ◽  
Drilling Operations

Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60

2014 ◽  
Vol 718 ◽  
pp. 93-98 ◽  
Author(s):  
Ján Duplák ◽  
Michal Hatala ◽  
Jozef Zajac ◽  
Karol Vasilko ◽  
Miroslav Kormoš ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Machining Process ◽  
Engineering Practice ◽  
Technical Standards ◽  
Sintered Carbide ◽  
Cutting Ceramic ◽  
Comprehensive Comparison ◽  
Steel Cutting

The main part of Standard ISO 3685 is T-vc dependence for various cutting materials. The Standard ISO 3685 contains main properties and characteristics for three most important cutting materials those are used in engineering practice. These cutting materials are used for cutting tools made of high speed steel, cutting ceramic and sintered carbide. Some types of cutting materials are defined by means of descriptions in standards ISO, some types by means of catalogues from the manufacturer. There are a lot of types of cutting materials they have not been defined theirs properties exactly yet and theirs properties have to be defined on experiments. There is a presumption that descriptions in standards ISO are not correct and these standards have to be examined and verified, because that this fact have to be confirmed or disproved. Accuracy and completeness technical standards ISO are very important part quality of manufacturing. Article describes process how to define T-vc dependence for cutting tools made of high speed steel, cutting ceramic and sintered carbide, because were found deficiencies in valid standard ISO 3685.

Durability Analysis for Selected Cutting Tools in Machining Process of Steel 16MoV6-3

2013 ◽  
Vol 308 ◽  
pp. 133-139 ◽  
Author(s):  
Ján Duplák ◽  
Michal Hatala ◽  
Peter Michalik
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Machining Process ◽  
Technical Science ◽  
Sintered Carbide ◽  
Durability Analysis ◽  
Tool Durability

Durability of cutting tool defines lifetime of this cutting tool and it determines its suitability for select technological operation. Technical science defines a lot of different factors, that they may be cause of shorter cutting tool lifetime. For increase cutting tool durability is necessary maximally possible elimination of these factors. Determination of cutting tool durability is very important, because provides comprehensive information how to determine appropriate technological conditions for selected cutting tool. In engineering is for determination of cutting tools durability used T-vc dependence. Durability of cutting tools is defined in standard ISO 3685. In standard ISO 3685 is defined T-vc dependence for different cutting materials and standard included process evaluation of tool durability for cutting materials made of high speed steel, sintered carbide and cutting ceramic. Specification of cutting tools durability in machining process of steel 16MoV6-3 is very important for economics of small and medium-sized enterprises, because cutting tool durability is factor that significantly affects the budget of these enterprises. Standard ISO 3685 contains instructions how to create T-vc dependence for cutting tools. In this standard are only instructions how to create T-vc dependence according to Mr. Taylor. The article describes process how to create durability dependence for cutting tools made of sintered carbide in machining process of 16MoV6-3 by means of T-vc dependence.

Detail Study and Analysis of Durability for Selected Cutting Materials According to Taylor's Theory

2013 ◽  
Vol 581 ◽  
pp. 3-8
Author(s):  
Ján Duplák ◽  
Matúš Čuma ◽  
Miroslav Kormoš
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Engineering Practice ◽  
Technical Standards ◽  
Sintered Carbide ◽  
Part Quality ◽  
Cutting Ceramic ◽  
Steel Cutting

The main part of Standard ISO 3685 is T-vc dependence for various cutting materials. The Standard ISO 3685 contains main properties and characteristics for three most important cutting materials those are used in engineering practice. These cutting materials are used for cutting tools made of high speed steel, cutting ceramic and sintered carbide. Some types of cutting materials are defined by means of descriptions in standards ISO, some types by means of catalogues from the manufacturer. There are a lot of types of cutting materials they have not been defined theirs properties exactly yet and theirs properties have to be defined on experiments. There is a presumption that descriptions in standards ISO are not correct and these standards have to be examined and verified, because that this fact have to be confirmed or disproved. Accuracy and completeness technical standards ISO are very important part quality of manufacturing. Article describes process how to define T-vc dependence for cutting tools made of high speed steel, cutting ceramic and sintered carbide, because were found deficiencies in valid standard ISO 3685.

Material characterization of tribological effects in HSS hacksaw blade

2017 ◽  
Vol 69 (3) ◽  
pp. 355-362
Author(s):  
Nor Amirah binti Mohd Amran ◽  
Mohd Sayuti bin Ab Karim ◽  
Rusdi bin Abd Rashid ◽  
Waleed Alghani ◽  
Nur Aqilah binti Derahman
Keyword(s):  
Mechanical Properties ◽  
High Speed ◽  
High Speed Steel ◽  
Hardness Test ◽  
Vital Role ◽  
Von Mises Stress ◽  
Content Type ◽  
Cultural Aspects ◽  
Von Mises

Purpose This study aims to present a direct repurposing activity of consumed high-speed steel (HSS) hacksaw blade into fine-looking handmade knives to increase the awareness about sustainability by evaluating the relationship between the quality of material alloys and heat treatment as well as cultural aspects such as the treatment on the HSS hacksaw blade that will affect the material hardness. Design/methodology/approach The quality of HSS hacksaw blade samples was analyzed by using scanning electron microscope/energy dispersive X-Ray spectroscopy (SEM/EDX) through the identification of material element’s properties. Besides, finite element structural analysis was performed by using SolidWorks Simulation to evaluate the material performance by determining the Von Mises stress to find the factor of safety of the knife designs. Then, the effect of tribology implementation toward mechanical properties of the handmade knives was determined by using a Rockwell C hardness test. Findings It is found that the material composition of carbon plays a vital role in increasing and improving the hardness and wear resistance of the HSS hacksaw blade. The Von Mises stress obtained is lower than the yield strength of 3,250 MPa by 71.44 per cent with the safety factor of 3.58,which means the design will not be subjected to failure. The mechanical properties of the HSS hacksaw blade such as hardness were determined averagely by 5 per cent of hardness increase. Originality/value It has been validated that the tribological effect toward the material characteristic leads to hardness changes which contributed to the enhancement of tool life of the HSS hacksaw blade, thus producing better quality knives.

scholarly journals Tool Wear and Surface Evaluation in Drilling Fly Ash Geopolymer Using HSS, HSS-Co, and HSS-TiN Cutting Tools

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1628
Author(s):  
Mohd Fathullah Ghazali ◽  
Mohd Mustafa Al Bakri Abdullah ◽  
Shayfull Zamree Abd Rahim ◽  
Joanna Gondro ◽  
Paweł Pietrusiewicz ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Flank Wear ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Spindle Speed ◽  
Drilling Process ◽  
Potential Use

This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.

Analysis of Selected Properties of Cutting Ceramics at Machining Process of Bearing Steel 100Cr6

2014 ◽  
Vol 616 ◽  
pp. 308-316 ◽  
Author(s):  
Anton Panda ◽  
Ján Duplák ◽  
Marek Prislupčák ◽  
Pavol Kokuľa
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Bearing Steel ◽  
Machining Process ◽  
Cutting Ceramic ◽  
Cutting Ceramics ◽  
Bearing Rings ◽  
Tool Durability

Cutting tool durability is very important cutting tool property. Especially for cutting ceramic is necessary to define durability dependence on available set of cutting speeds and to determine lifetime of tools made of cutting ceramic. Durability of cutting tools is defined in standard ISO 3685. In standard ISO 3685 is defined T-vc dependence for different cutting materials and standard included process evaluation of tool durability for cutting materials made of high speed steel, sintered carbide and cutting ceramic. Specification cutting tools durability made of cutting ceramic in machining process of steel 100Cr6 is very important for economics of small and medium-sized enterprises, because cutting tool durability is factor that significantly affects the budget of these enterprises. This problematic is determined for small and medium-sized manufacturers of bearings, because steel 100Cr6 is most commonly used for production of bearing rings 100 mm in diameter. This material is usable for actuator (actuators and reduction gears) too. Description of cutting ceramic durability could mean for bearings manufacturer determination of optimal cutting parameter with maximum possible use of tool lifetime. Standard ISO 3685 contains instructions how to create T-vc dependence for cutting tools made of cutting ceramic. In this standard are only instructions how to create T-vc dependence according to Taylor. The article compares T-vc dependencies for various cutting ceramics (Al2O3, Al2O3+ZrO2, Al2O3+TiCN) with T-vc dependence defined in standard ISO 3685, because this standard describes T-vc dependence for all entered cutting materials together.

Roller Bearings and Analytical Expression of Selected Cutting Tools Durability in Machining Process of Steel 80MoCrV4016

2013 ◽  
Vol 415 ◽  
pp. 610-613 ◽  
Author(s):  
Anton Panda ◽  
Ján Duplák ◽  
Jozef Jurko ◽  
Iveta Pandová
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Machining Process ◽  
Engineering Practice ◽  
Technical Science ◽  
Analytical Expression ◽  
Comprehensive Information ◽  
Tool Durability

Technical science defines a lot of different factors, that they may be cause of shorter cutting tool lifetime. For increase of cutting tool durability is necessary maximally possible elimination of these factors. Determination of cutting tool durability is very important, because provides comprehensive information how to determine appropriate technological conditions for selected cutting tool. The analytical expression of dependence represents very important part of experiments, because all tested processes can be described and defined by formula. These instructions, how to proceed in experiments are obtained in standard ISO 3685. Very important and often used standard ISO in engineering practice is standard ISO 3685. The main part of this standard is T-vc dependence for cutting materials. In standard ISO 3685 are included cutting materials made of high speed steel, sintered carbide and cutting ceramic. The article describes process how to define and to analytically express T-vc dependence for cutting tools made of ceramic in machining process of steel 80MoCrV4016.

scholarly journals An experimental investigation of the effects of point angle on the high-speed steel drills performance in drilling

2018 ◽  
Vol 51 (9-10) ◽  
pp. 417-430 ◽  
Author(s):  
Zülküf Demir
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Cutting Edge ◽  
Drilling Process ◽  
Cutting Speeds

The differences in the cutting speed are a serious problem along the cutting edge of the drill, in drilling operations. This problem can partly be solved reducing the length of the cutting edge via changing the drill point angle. In addition, in this study, the effect of point angle, feed rate, and cutting speed on drilling is investigated. For identifying the optimum cutting parameters, AISI 1050 steel alloy was selected as the experimental specimen, these specimen were pre-drilled 5 mm in diameter due to eliminating the effect of the chisel edge. In the experiments, the holes were drilled only at a depth of 10 mm in order not to give any harm to the dynamometer while measuring thrust force. For this aim, in drilling process, drills with point angle of 100°, 118°, 136°, 154°, and 172° were selected. In conclusion, the thrust force, the tool wear, and the surface roughness linearly decreased with increasing point angles due to less removal chip area, in per revolve of the tool. However, the thrust force, the tool wear, and the surface roughness were adversely affected at higher feed rates and lower cutting speeds. The hole dimensional accuracy decreased at lower feed rates and cutting speeds but at higher point angles and concurrently at higher feed rates but lower point angles and cutting speeds. However, the hole dimensional accuracy showed more decisiveness at 118° than other point angles, while the highest dimensional accuracy values recorded at 136° point angle, at higher cutting speeds.

Mechano-Chemical Surface Modification of High-Speed Steel Cutting Tools

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Ye Qi ◽  
Vinh Nguyen ◽  
Shreyes Melkote ◽  
Michael Varenberg
Keyword(s):  
Surface Modification ◽  
High Speed ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Base Oil ◽  
Chemical Surface ◽  
Chemical Surface Modification

In this work, a mechano-chemical surface modification to improve cutting tool performance is proposed. We applied this surface modification via shot peening the rake faces of high-speed steel tools with a blend of Al2O3 and Cu2S particles that serve as a plastic deformation medium and a chemical precursor, respectively. Orthogonal cutting experiments under base oil lubrication demonstrated that the proposed treatment results in a reduction of cutting and thrust forces, as well as in a reduction of built-up edge formation. These effects are explained by favorable changes in the lubricity and roughness of the rake face, and they suggest that this method has the potential to increase cutting tool life, lower energy consumption, and improve the dimensional accuracy and surface quality of a machined workpiece.

scholarly journals Cutting Environment Impact on the Aluminium Alloy Machining

2019 ◽  
Vol 27 (44) ◽  
pp. 21-27
Author(s):  
Eva Buranská ◽  
Ivan Buranský ◽  
Michaela Kritikos ◽  
Kristína Gerulová ◽  
Ján Líška
Keyword(s):  
High Speed ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Quality Characteristics ◽  
Machining Process ◽  
Machining Parameters ◽  
Environment Impact ◽  
Multicriterial Optimization ◽  
Optimal Cutting Parameters

Abstract The paper is focused on the experiment where the effects of the cutting environment and feed of drilling on the bores roughness and cylindricity were evaluated. Dry drilling of aluminium alloys (without using cutting fluids) is an environmentally friendly machining process but also an extremely difficult task, which is due to the tendency of aluminium to adhere to the drills made of conventional materials such as high-speed steel; and therefore three cutting environments (namely two different emulsions and compressed air) were used in the experiment. The article demonstrates multicriterial optimization of input factors (cutting environment, feed) for two defined target functions: roughness and cylindricity). The measured values were subjected to mathematico–statistical Analysis of Variance (ANOVA). ANOVA was used for examining the effects of machining parameters and their contribution to the surface roughness and bores cylindricity. The optimal cutting parameters were evaluated for “Smaller-the-Better” quality characteristics of both output responses, as can be seen in our article published previously. Based on the ANOVA, we determined that cutting environment exhibited higher percentage of contribution on bores quality than feed of machining. The results show 77.37 % impact of cutting environment and 8.13 % impact of feed on quality of machined bores.

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