Effect of Dry Cutting on Force and Tool Life When Machining Aerospace Material
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.
[1] Richards N, Aspinwall D. Use of ceramic tools for machining
nickelbased alloys. Int J Mach Tool Manf 1989;294:575-88.
[2] Khamsehzadeh H. Behaviour of ceramic cutting tools when machining
superalloys. Ph.D. thesis, University of Warwick; 1991. p. 125.
[3] Ezugwu EO, Machado AR, Pashby IR, Wallbank J. The effect of highpressure
coolant supply. Lub Eng 1990;479:751-7.
[4] Ezugwu EO, Wang ZM. Performance of PVD and CVD coated tools
when nickel-based machining Inconel 718 alloy. In: Narutaki N, et al.,
editors. Progress of cutting and grinding; 1996. p. 111:102-7.
[5] Wang ZM. Titanium alloys and their machinability with coated carbide
inserts. Ph.D. thesis, South Bank University, London, UK; 1997. p. 78-
9, 247.
[6] Li L, He N, Wang M, Wang ZG. High speed cutting of Inconel 718 with
coated carbide and ceramic inserts. J Mater Process Technol
2002;129:127-30.
[7] Metal cutting theory and practice by David a. Stephenson and John
S.Agapiou, publish by Marcel Dekker, Inc, 1997.
[8] Metal Cutting Mechanics by Viktor P.Astakhov, publish by CRC press,
1999.
[9] Manufacturing Process and Systems, Ninth Edition; by Philip F.Ostwald
and Jairo Munoz, publish by John Wiley & Son.
[10] Workshop Technology Volume 2; by HS Bawa;publish by Tata
McGraw-Hill;1995.
[11] Alauddin, M., Baradie, M.A.E., Hashmi, M.S.J., 1995. Computer-aided
analysis of a surface-roughnessmodel for endmilling. J.Mater. Process.
Technol. 55, 123-127.
[12] Davim, J.P., 2003. Design of optimization of cutting parameters for
turning metal matrix composites based on the orthogonal arrays. J.
Mater. Process. Technol.132, 340-344.
[13] Ghani, J.A., Choudhury, I.A.,Hassan,H.H., 2004. Application of Taguchi
method in the optimization of end milling parameters. J. Mater. Process.
Technol. 145, 84-92.
[14] Reddy, N.S.K., Rao, P.V., 2005. Experimental investigation to study the
effect of solid lubricants on cutting forces and surface quality in
endmilling. Int. J.Mach. Tools Manuf. 45, 1-10.
[15] Lin, T., Chananda, B., 2004. Quality improvement of an injectionmolded
product using design of experiments: a case study. Qual. Eng. 16
(1), 99-104.
[16] Puertas, I., Luis, C.J., 2004. A study of optimization of machining
parameters for electrical discharge machining of boron carbide. Mater.
Manuf. Process. 19 (6),1041-1070.
[17] Alagumurthi, N., Palaniradja, K., Soundararajan, V., 2006. Optimization
of grinding process through design of experiment (DOE)ÔÇöa
comparative study. Mater.Manuf. Process. 21 (1), 19-21.
[18] Yijian Liu, Xiongxiong He "Modeling Identification of Power Plant
Thermal Process Based on PSO Algorithm" American Control
Conference, Portland, USA, June 8-10, 2005.
[19] Jialin Zhou, Zhengcheng Duana, Yong Lia, Jianchun Denga and
Daoyuan Yua," PSO-based neural network optimization and its
utilization in a boring machine", Journal of Materials Processing
Technology,178(1-3), pp.19 - 23. doi:10.1016/j.jmatprotec.2005.07.002.
[20] Chia-Nan Koa,Ying-Pin Changb, and Chia-Ju Wuc," An orthogonalarray-
based particle swarm optimizer with nonlinear time-varying
evolution", Applied Mathematics and Computation, 191(1), pp. 272 -
279. doi:10.1016/j.amc.2007.02.096.
[21] Ying-Pin Changa and Chia-Nan Kob," A PSO method with nonlinear
time-varying evolution based on neural network for design of optimal
harmonic filters", Expert Systems with Applications, 36(3), pp. 6809-
6816. doi:10.1016/j.eswa.2008.08.007.
[22] Hui Pan, Ling Wanga and Bo Liu," Particle swarm optimization for
function optimization in noisy environment", Applied Mathematics and
Computation, 181(2), pp. 908 - 919. doi:10.1016/j.amc.2006.01.066.
[23] Bhattacharya SK, Pashby IR, Ezugwu EO. Machining of INCO 718 and
INCO 901 superalloys with Sic-whisker reinforced Al2O3 composite
ceramic tools. Prod Eng 1987:176-81.
[24] Bhattacharya SK, Jawid A, Lewis MH. Behaviour of sialon ceramic
tools when machining cast iron. In: Proceedings of the 12th North
American manufacturing research conference; 1984. p. 265-70.
[25] Chow CB, Liu YH, Miao HC, Lo ZP. Investigation on the cutting
performance of silicon nitride ceramic tools. In: International conference
manufacturing engineering; 1980. p. 71-4.
[26] Ezugwu EO, Machado AR. Face milling of aerospace materials. In:
Proceedings of the 1st international conference on behaviour of
materials in machining; 1988. p. 3.1-11.
[1] Richards N, Aspinwall D. Use of ceramic tools for machining
nickelbased alloys. Int J Mach Tool Manf 1989;294:575-88.
[2] Khamsehzadeh H. Behaviour of ceramic cutting tools when machining
superalloys. Ph.D. thesis, University of Warwick; 1991. p. 125.
[3] Ezugwu EO, Machado AR, Pashby IR, Wallbank J. The effect of highpressure
coolant supply. Lub Eng 1990;479:751-7.
[4] Ezugwu EO, Wang ZM. Performance of PVD and CVD coated tools
when nickel-based machining Inconel 718 alloy. In: Narutaki N, et al.,
editors. Progress of cutting and grinding; 1996. p. 111:102-7.
[5] Wang ZM. Titanium alloys and their machinability with coated carbide
inserts. Ph.D. thesis, South Bank University, London, UK; 1997. p. 78-
9, 247.
[6] Li L, He N, Wang M, Wang ZG. High speed cutting of Inconel 718 with
coated carbide and ceramic inserts. J Mater Process Technol
2002;129:127-30.
[7] Metal cutting theory and practice by David a. Stephenson and John
S.Agapiou, publish by Marcel Dekker, Inc, 1997.
[8] Metal Cutting Mechanics by Viktor P.Astakhov, publish by CRC press,
1999.
[9] Manufacturing Process and Systems, Ninth Edition; by Philip F.Ostwald
and Jairo Munoz, publish by John Wiley & Son.
[10] Workshop Technology Volume 2; by HS Bawa;publish by Tata
McGraw-Hill;1995.
[11] Alauddin, M., Baradie, M.A.E., Hashmi, M.S.J., 1995. Computer-aided
analysis of a surface-roughnessmodel for endmilling. J.Mater. Process.
Technol. 55, 123-127.
[12] Davim, J.P., 2003. Design of optimization of cutting parameters for
turning metal matrix composites based on the orthogonal arrays. J.
Mater. Process. Technol.132, 340-344.
[13] Ghani, J.A., Choudhury, I.A.,Hassan,H.H., 2004. Application of Taguchi
method in the optimization of end milling parameters. J. Mater. Process.
Technol. 145, 84-92.
[14] Reddy, N.S.K., Rao, P.V., 2005. Experimental investigation to study the
effect of solid lubricants on cutting forces and surface quality in
endmilling. Int. J.Mach. Tools Manuf. 45, 1-10.
[15] Lin, T., Chananda, B., 2004. Quality improvement of an injectionmolded
product using design of experiments: a case study. Qual. Eng. 16
(1), 99-104.
[16] Puertas, I., Luis, C.J., 2004. A study of optimization of machining
parameters for electrical discharge machining of boron carbide. Mater.
Manuf. Process. 19 (6),1041-1070.
[17] Alagumurthi, N., Palaniradja, K., Soundararajan, V., 2006. Optimization
of grinding process through design of experiment (DOE)ÔÇöa
comparative study. Mater.Manuf. Process. 21 (1), 19-21.
[18] Yijian Liu, Xiongxiong He "Modeling Identification of Power Plant
Thermal Process Based on PSO Algorithm" American Control
Conference, Portland, USA, June 8-10, 2005.
[19] Jialin Zhou, Zhengcheng Duana, Yong Lia, Jianchun Denga and
Daoyuan Yua," PSO-based neural network optimization and its
utilization in a boring machine", Journal of Materials Processing
Technology,178(1-3), pp.19 - 23. doi:10.1016/j.jmatprotec.2005.07.002.
[20] Chia-Nan Koa,Ying-Pin Changb, and Chia-Ju Wuc," An orthogonalarray-
based particle swarm optimizer with nonlinear time-varying
evolution", Applied Mathematics and Computation, 191(1), pp. 272 -
279. doi:10.1016/j.amc.2007.02.096.
[21] Ying-Pin Changa and Chia-Nan Kob," A PSO method with nonlinear
time-varying evolution based on neural network for design of optimal
harmonic filters", Expert Systems with Applications, 36(3), pp. 6809-
6816. doi:10.1016/j.eswa.2008.08.007.
[22] Hui Pan, Ling Wanga and Bo Liu," Particle swarm optimization for
function optimization in noisy environment", Applied Mathematics and
Computation, 181(2), pp. 908 - 919. doi:10.1016/j.amc.2006.01.066.
[23] Bhattacharya SK, Pashby IR, Ezugwu EO. Machining of INCO 718 and
INCO 901 superalloys with Sic-whisker reinforced Al2O3 composite
ceramic tools. Prod Eng 1987:176-81.
[24] Bhattacharya SK, Jawid A, Lewis MH. Behaviour of sialon ceramic
tools when machining cast iron. In: Proceedings of the 12th North
American manufacturing research conference; 1984. p. 265-70.
[25] Chow CB, Liu YH, Miao HC, Lo ZP. Investigation on the cutting
performance of silicon nitride ceramic tools. In: International conference
manufacturing engineering; 1980. p. 71-4.
[26] Ezugwu EO, Machado AR. Face milling of aerospace materials. In:
Proceedings of the 1st international conference on behaviour of
materials in machining; 1988. p. 3.1-11.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:58744", author = "K.Kadirgama and M.M.Noor and K.A. Abou-El-Hossein and H.H.Habeeb and M.M. Rahman and B.Mohamad and R.A. Bakar", title = "Effect of Dry Cutting on Force and Tool Life When Machining Aerospace Material", 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.", keywords = "Dry cutting, partial swarm optimisation, response
surface method, tool life", volume = "4", number = "11", pages = "1262-5", }
