Comparison of the machinability of the 316L and 18Ni300 additively manufactured steels based on turning tests

This paper focuses on the machinability of additively manufactured steel alloys (316L stainless steel and 18Ni300 Maraging steel) by reference to their conventional metallurgical conditions. The machinability of both metallurgical conditions has been evaluated by longitudinal turning tests under laboratory conditions using two different cutting tool geometries (flat rake face and chip-breaker geometry) and covering different cutting speeds, depths of cut and feed values. Cutting forces, chip morphology and surface roughness were investigated as machinability indicators. The influence of chip-breaker on process performance was also analysed. For a comprehensive discussion of the results, microstructure, chemical composition, surface roughness and mechanical strength of both metallurgical conditions were studied. The paper quantitatively demonstrates that despite the higher mechanical strength of additively manufactured alloys, no significant power requirements were verified for the finishing cutting of tested alloys, when compared with conventional materials. Also noteworthy, is the surface quality improvement of the printed samples due to the most favourable conditions for chip formation. The usage of a chip breaker insert had higher impact on reducing required cutting energy than on controlling chip geometry.

Análise das superfícies de saída e de folga de ferramentas de corte empregadas no torneamento de ferro fundido cinzento perlítico com diferentes adições de nióbio

Cast iron corresponds to the second most used metallic material worldwide. However, its production has shown reductions, mainly due to the development of lighter materials. In this sense, metallurgical efforts have been made to add elements to obtain different solid solutions that would lead to the improvement and guarantee of the diversity of this alloy. However, modifications of any kind to the properties of a material have an impact on its machinability. Thus, this work aimed to evaluate the influence of the addition of niobium (0.21-0.24% by weight) in a pearlitic gray cast iron alloy (equivalent to the EN-GJL-250 class) on the wear of the tools of cemented carbide (class K20) during the turning. The wear on the rake and clearance surfaces was qualitatively evaluated via scanning electron microscopy (SEM) and X-ray dispersive energy spectroscopy (EDS). Together, the chemical composition variation occurred with the chip breaker geometry: tools with chip breaker (GH) or without chip breaker (Flat Top). All these variations were indifferent in relation to the wear of the tools and their mechanisms. Regardless of the chemical composition, material of the machined part was found adhered to both the rake surface and the clearance of all cutting tools. In addition, grooves were found in the flank, suggesting the abrasion mechanism.

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-based Design and Validation

Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

Turning Titanium Alloy, Grade 5 ELI, With the Implementation of High Pressure Coolant

In the machining of difficult-to-cut alloys, such as titanium-based alloys, the delivery of a cutting fluid with high pressure can increase machining efficiency and improve process stability through more efficient chip breaking and removing. Proper selection of machining conditions can increase the productivity of the process while minimizing production costs. To present the influence of cutting fluid pressure and chip breaker geometry on the chip breaking process for various chip cross-sections Grade 5 ELI titanium alloy turning tests were carried out using carbide tools, H13A grade, with a -SF chip breaker geometry under the cutting fluid pressure of 70 bar. Measurements of the total cutting force components for different cutting speeds, feeds, and cutting depth in finishing turning were carried out. The analysis of the obtained chips forms and the application area of the chip breaker have been presented. It was proved that for small depth of cut (leading to small chip cross-section) the cutting fluid pressure is the main cause of the chip breakage, since the insert chip breaker does not work. On the other hand, for bigger depths of cut where the chip breaker goes in action, the cutting fluid pressure only supports this process. For medium values of depths of cut the strength of chip is high enough so that the pressure of the cutting fluid cannot cause chip breaking. A chip groove is not filled completely so the chip breaker cannot play its role.

Investigation of Chip Deformation and Breaking with a Staggered Teeth BTA Tool in Deep Hole Drilling

The problem of chip breaking and evacuation is the key point of staggered teeth boring and trepanning association (BTA) drilling. The factors that influence chip breaking with staggered teeth BTA deep hole drilling are analyzed by using the chip bending deformation mechanism for chip formation and flow through the rake face and chip breaker. This study investigated the distribution and variation of chip deformation and breaking along drilling conditions, with respect to drilling radius, drilling process parameters, tool wear, and chip breaker geometric parameters. The results show that the tool-chip contact length is about 1.65 times the chip thickness in staggered teeth BTA drilling. The cutting radius of the teeth has a considerable influence on the chip thickness. Compared with the drilling speed, the feed has a greater impact on chip deformation and breaking, and the chip thickness and strain increase with increased feed. Increased drilling depth and tooth wear aggravates the friction state between the chip and the rake face, augments chip thickness and tool-chip contact length, and increases the chip’s strain increment. As the width of chip breaker decreases and the height increases, the chip strain increases and the breaking conditions are improved.