Abstract: Lubrication, cooling and chip removal are the desired functions of any cutting fluid. Conventional or flood lubrication requires high volume flow rate and cost associated with this is higher. In addition, flood lubrication possesses health risks to machine operator. To avoid these consequences, dry machining and minimum quantity are two alternatives. Dry machining cannot be a suited alternative as it can generate greater heat and poor surface finish. Here, turning work is carried out on a Lathe machine using EN3 Mild steel. Variable cutting speeds and depth of cuts are provided and corresponding temperatures and surface roughness values were recorded. Experimental results are analyzed by Minitab software. Regression analysis, main effect plot, and interaction plot conclusion are drawn by using ANOVA. There is a 95.83% reduction in the use of cutting fluid. MQL gives a 9.88% reduction in tool temperature, this will improve tool life. MQL produced a 17.64% improved surface finish. MQL appears to be an economical and environmentally compatible lubrication technique for sustainable manufacturing.
Abstract: Lubrication, cooling and chip removal are the desired functions of any cutting fluid. Conventional or flood lubrication requires high volume flow rate and cost associated with this is higher. In addition, flood lubrication possesses health risks to machine operator. To avoid these consequences, dry machining and minimum quantity are two alternatives. Dry machining cannot be a suited alternative as it can generate greater heat and poor surface finish. Here, turning work is carried out on a Lathe machine using EN3 Mild steel. Variable cutting speeds and depth of cuts are provided and corresponding temperatures and surface roughness values were recorded. Experimental results are analyzed by Minitab software. Regression analysis, main effect plot, and interaction plot conclusion are drawn by using ANOVA. There is a 95.83% reduction in the use of cutting fluid. MQL gives a 9.88% reduction in tool temperature, this will improve tool life. MQL produced a 17.64% improved surface finish. MQL appears to be an economical and environmentally compatible lubrication technique for sustainable manufacturing.
Abstract: Technological advancements in the development of cutting tools and coolant/lubricant chemistry have enhanced the machining capabilities of hard materials under higher machining conditions. Generation of high temperatures at the cutting zone during machining is one of the most important and pertinent problems which adversely affect the tool life and surface finish of the machined components. Generally, cutting fluids and solid lubricants are used to overcome the problem of heat generation, which is not effectively addressing the problems. With technological advancements in the field of tribology, nano-level particulate solid lubricants are being used nowadays in machining operations, especially in the areas of turning and grinding. The present investigation analyses the effect of using nano-particulate graphite powder as lubricant in the turning of AISI 1040 steel under variable machining conditions and to study its effect on cutting forces, tool temperature and surface roughness of the machined component. Experiments revealed that the increase in cutting forces and tool temperature resulting in the decrease of surface quality with the decrease in the size of nano-particulate graphite powder as lubricant.
Abstract: Tungsten carbide is widely used as a tool material in metal manufacturing process. Since tungsten is typical rare metal, establishment of recycle process of tungsten carbide tools and restore into cemented carbide material bring great impact to metal manufacturing industry. Recently, recycle process of tungsten carbide has been developed and established gradually. However, the demands for quality of cemented carbide tool are quite severe because hardness, toughness, anti-wear ability, heat resistance, fatigue strength and so on should be guaranteed for precision machining and tool life. Currently, it is hard to restore the recycled tungsten carbide powder entirely as raw material for new processed cemented carbide tool. In this study, to suggest positive use of recycled tungsten carbide powder, we have tried to fabricate a carbon based sintered steel which shows reinforced mechanical properties with recycled tungsten carbide powder. We have made set of newly designed sintered steels. Compression test of sintered specimen in density ratio of 0.85 (which means 15% porosity inside) has been conducted. As results, at least 1.7 times higher in nominal strength in the amount of 7.0 wt.% was shown in recycled WC powder. The strength reached to over 600 MPa for the Fe-WC-Co-Cu sintered alloy. Wear test has been conducted by using ball-on-disk type friction tester using 5 mm diameter ball with normal force of 2 N in the dry conditions. Wear amount after 1,000 m running distance shows that about 1.5 times longer life was shown in designed sintered alloy. Since results of tensile test showed that same tendency in previous testing, it is concluded that designed sintered alloy can be used for several mechanical parts with special strength and anti-wear ability in relatively low cost due to recycled tungsten carbide powder.
Abstract: In machining, there is always a problem with heat generation and friction produced during the process as they consequently affect tool wear and surface finish. An instant heat transfer mechanism could protect the cutting tool edge and enhance the tool life by cooling the cutting edge of the tool. In the present work, carbon nanotube (CNT) based nano-cutting fluid is proposed for machining a hard-to-cut material. Tool wear and surface roughness are considered for the evaluation of the nano-cutting fluid in turning process. The performance of nanocoolant is assessed against the conventional coolant and dry machining conditions and it is observed that the proposed nanocoolant has produced better performance than the conventional coolant.
Abstract: Machining of Metal Matrix Composites (MMCs) is very significant process and has been a main problem that draws many researchers to investigate the characteristics of MMCs during different machining process. The poor machining properties of hard particles reinforced MMCs make drilling process a rather interesting task. Unlike drilling of conventional materials, many problems can be seriously encountered during drilling of MMCs, such as tool wear and cutting forces. Cutting tool wear is a very significant concern in industries. Cutting tool wear not only influences the quality of the drilled hole, but also affects the cutting tool life. Prediction the cutting tool life during drilling is essential for optimizing the cutting conditions. However, the relationship between tool life and cutting conditions, tool geometrical factors and workpiece material properties has not yet been established by any machining theory. In this research work, fuzzy subtractive clustering system has been used to model the cutting tool life in drilling of Al2O3 particle reinforced aluminum alloy composite to investigate of the effect of cutting conditions on cutting tool life. This investigation can help in controlling and optimizing of cutting conditions when the process parameters are adjusted. The built model for prediction the tool life is identified by using drill diameter, cutting speed, and cutting feed rate as input data. The validity of the model was confirmed by the examinations under various cutting conditions. Experimental results have shown the efficiency of the model to predict cutting tool life.
Abstract: Chatter vibrations, occurring during cutting process,
cause vibration between the cutting tool and workpiece, which
deteriorates surface roughness and reduces tool life. The purpose of
this study is to investigate the influence of cutting parameters and
tool construction on surface roughness and vibration in turning of
aluminum alloy AA2024. A new design of cutting tool is proposed,
which is filled up with epoxy granite in order to improve damping
capacity of the tool. Experiments were performed at the lathe using
carbide cutting insert coated with TiC and two different cutting tools
made of AISI 5140 steel. Taguchi L9 orthogonal array was applied to
design of experiment and to optimize cutting conditions. By the help
of signal-to-noise ratio and analysis of variance the optimal cutting
condition and the effect of the cutting parameters on surface
roughness and vibration were determined. Effectiveness of Taguchi
method was verified by confirmation test. It was revealed that new
cutting tool with epoxy granite has reduced vibration and surface
roughness due to high damping properties of epoxy granite in
toolholder.
Abstract: Machining of hard materials is a recent technology for
direct production of work-pieces. The primary challenge in
machining these materials is selection of cutting tool inserts which
facilitates an extended tool life and high-precision machining of the
component. These materials are widely for making precision parts for
the aerospace industry. Nickel-based alloys are typically used in
extreme environment applications where a combination of strength,
corrosion resistance and oxidation resistance material characteristics
are required. The present paper reports the theoretical and
experimental investigations carried out to understand the influence of
machining parameters on the response parameters. Considering the
basic machining parameters (speed, feed and depth of cut) a study has
been conducted to observe their influence on material removal rate,
surface roughness, cutting forces and corresponding tool wear.
Experiments are designed and conducted with the help of Central
Composite Rotatable Design technique. The results reveals that for a
given range of process parameters, material removal rate is favorable
for higher depths of cut and low feed rate for cutting forces. Low feed
rates and high values of rotational speeds are suitable for better finish
and higher tool life.
Abstract: Metal matrix composites (MMCs) attract considerable
attention as a result from its ability in providing a high strength, high
modulus, high toughness, high impact properties, improving wear
resistance and providing good corrosion resistance compared to
unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been
widely used in various industrial sectors such as in transportation,
domestic equipment, aerospace, military, construction, etc.
Aluminium silicon alloy is an MMC that had been reinforced with
aluminium nitrate (AlN) particle and become a new generation
material use in automotive and aerospace sector. The AlN is one of
the advance material that have a bright prospect in future since it has
features such as lightweight, high strength, high hardness and
stiffness quality. However, the high degree of ceramic particle
reinforcement and the irregular nature of the particles along the
matrix material that contribute to its low density is the main problem
which leads to difficulties in machining process. This paper examined
the tool wear when milling AlSi/AlN Metal Matrix Composite using
a TiB2 (Titanium diboride) coated carbide cutting tool. The volume
of the AlN reinforced particle was 10% and milling process was
carried out under dry cutting condition. The TiB2 coated carbide
insert parameters used were at the cutting speed of (230, 300 and
370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The
Sometech SV-35 video microscope system used to quantify of the
tool wear. The result shown that tool life span increasing with the
cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at
0.4mm) which constituted an optimum condition for longer tool life
lasted until 123.2 mins. Meanwhile, at medium cutting speed which
at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we
found that tool life span lasted until 119.86 mins while at low cutting
speed it lasted in 119.66 mins. High cutting speed will give the best
parameter in cutting AlSi/AlN MMCs material. The result will help
manufacturers in machining process of AlSi/AlN MMCs materials.
Abstract: Paper is dealing by testing of IN23 ceramic cutting tools at irregular shocks at special fixture - interrupted cut simulator. Standard tests provided at fixture were at regular interrupted cut at 4 slats by 90°. These new tests will be at irregular cut for 1 slat, 2 slats against each other, 2 slats side by side, 3 slats and 4 slats. The main goal is check if irregular shocks have influence at mechanical and thermal shock at tool life of cutting inserts.
Abstract: The article deals with the possibilities of increasing the efficiency of turning thin-walled workpieces. It proposes a new strategy for turning and it proposes new implementation of roughing cycles where a variable depth of cut is applied. Proposed roughing cycles are created in the CAD/CAM system. These roughing cycles are described in relation to their further use in practice.
The experimental research has focused on monitoring the durability of cutting tool and increases its tool life. It compares the turning where the standard roughing cycle is used and the turning where the proposed roughing cycle with variable depth of cut is applied. In article are monitored tool wear during cutting with the sintered carbide cutting edge. The result verifies theoretical prerequisites of tool wear.
Abstract: Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.
Abstract: This work deals with problems of tool axis inclination angles in ball-end milling. Tool axis inclination angle contributes to improvement of functional surface properties (surface integrity - surface roughness, residual stress, micro hardness, etc.), decreasing cutting forces and improving production. By milling with ball-end milling tool, using standard way of cutting, when work piece and cutting tool contain right angle, we have zero cutting speed on edge. At this point cutting tool only pushes material into the work piece. Here we can observe the following undesirable effects - chip contraction, increasing of cutting temperature, increasing vibrations or creation of built-up edge. These effects have negative results – low quality of surface and decreasing of tool life (in the worse case even it is pinching out). These effects can be eliminated with the tilt of cutting tool or tilt of work piece.
Abstract: In the present paper, the three-dimensional
temperature field of tool is determined during the machining and
compared with experimental work on C45 workpiece using carbide
cutting tool inserts. During the metal cutting operations, high
temperature is generated in the tool cutting edge which influence on
the rate of tool wear. Temperature is most important characteristic of
machining processes; since many parameters such as cutting speed,
surface quality and cutting forces depend on the temperature and high
temperatures can cause high mechanical stresses which lead to early
tool wear and reduce tool life. Therefore, considerable attention is
paid to determine tool temperatures. The experiments are carried out
for dry and orthogonal machining condition. The results show that
the increase of tool temperature depends on depth of cut and
especially cutting speed in high range of cutting conditions.
Abstract: The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the new three parameters are introduced from three dynamic cutting forces, which are calculated by taking the ratio of the average variances of dynamic cutting forces to the absolute variances of themselves. It had been proved that the chatter can be easier to detect during the in-process cutting by using the new parameters which are proposed in this research. The experimentally obtained results showed that the wavelet transform can provide the reliable results to detect the chatter under various cutting conditions.
Abstract: This paper presents an experimental investigation on
the machinability of laser-sintered material using small ball end mill focusing on wear mechanisms. Laser-sintered material was produced
by irradiating a laser beam on a layer of loose fine SCM-Ni-Cu powder. Bulk carbon steel JIS S55C was selected as a reference steel.
The effects of powder consolidation mechanisms and unsintered
powder on the tool life and wear mechanisms were carried out. Results indicated that tool life in cutting laser-sintered material is
lower than that in cutting JIS S55C. Adhesion of the work material and chipping were the main wear mechanisms of the ball end mill in
cutting laser-sintered material. Cutting with the unsintered powder
surrounding the tool and laser-sintered material had caused major fracture on the cutting edge.
Abstract: This paper deals with the problem of thermal and
mechanical shocks, which rising during operation, mostly at
interrupted cut. Here will be solved their impact on the cutting edge
tool life, the impact of coating technology on resistance to shocks
and experimental determination of tool life in heating flame.
Resistance of removable cutting edges against thermal and
mechanical shock is an important indicator of quality as well as its
abrasion resistance. Breach of the edge or its crumble may occur due
to cyclic loading. We can observe it not only during the interrupted
cutting (milling, turning areas abandoned hole or slot), but also in
continuous cutting. This is due to the volatility of cutting force on
cutting. Frequency of the volatility in this case depends on the type
of rising chips (chip size element). For difficult-to-machine materials
such as austenitic steel particularly happened at higher cutting speeds
for the localization of plastic deformation in the shear plane and for
the inception of separate elements substantially continuous chips.
This leads to variations of cutting forces substantially greater than for
other types of steel.
Abstract: Cutting fluids, usually in the form of a liquid, are
applied to the chip formation zone in order to improve the cutting
conditions. Cutting fluid can be expensive and represents a biological
and environmental hazard that requires proper recycling and
disposal, thus adding to the cost of the machining operation. For
these reasons dry cutting or dry machining has become an
increasingly important approach; in dry machining no coolant or
lubricant is used. This paper discussed the effect of the dry cutting on
cutting force and tool life when machining aerospace materials
(Haynes 242) with using two different coated carbide cutting tools
(TiAlN and TiN/MT-TiCN/TiN). Response surface method (RSM)
was used to minimize the number of experiments. ParTiAlN Swarm
Optimisation (PSO) models were developed to optimize the
machining parameters (cutting speed, federate and axial depth) and
obtain the optimum cutting force and tool life. It observed that
carbide cutting tool coated with TiAlN performed better in dry
cutting compared with TiN/MT-TiCN/TiN. On other hand, TiAlN
performed more superior with using of 100 % water soluble coolant.
Due to the high temperature produced by aerospace materials, the
cutting tool still required lubricant to sustain the heat transfer from
the workpiece.
Abstract: The aim of this investigation is to study the
performance of the new generation of the PVD coated grade and to
map the influence of cutting conditions on the tool life in milling of
ADI (Austempered Ductile Iron). The results show that chipping is
the main wear mechanism which determines the tool life in dry
condition and notch wear in wet condition for this application. This
due to the different stress mechanisms and preexisting cracks in the
coating. The wear development shows clearly that the new PVD
coating (C20) has the best ability to delay the chipping growth. It
was also found that a high content of Al in the new coating (C20)
was especially favorable compared to a TiAlN multilayer with lower
Al content (C30) or CVD coating. This is due to fine grains and low
compressive stress level in the coating which increase the coating
ability to withstand the mechanical and thermal impact. It was also
found that the use of coolant decreases the tool life with 70-80%
compare to dry milling.
Abstract: In this paper, the wear of high speed steel hobs during
hobbing has been studied. The wear mechanisms are strongly
influenced by the choice of cutting speed. At moderate and high
cutting speeds three major wear mechanisms were identified:
abrasion, mild adhesive and severe adhesive. The microstructure and
wear behavior of two high speed steel grades (M2 and ASP30) has
been compared. In contrast, a variation in chemical composition or
microstructure of HSS tool material generally did not change the
dominant wear mechanism. However, the tool material properties
determine the resistance against the operating wear mechanism and
consequently the tool life. The metallographic analysis and wear
measurement at the tip of hob teeth included scanning electron
microscopy and stereoscope microscopy. Roughness profilometery is
used for measuring the gear surface roughness.