Abstract: In this work, a cooling coherent round nozzle was developed and the impact of nozzle placement (i.e. nozzle angle and stand-off/impinging distance) on the machinability of Ti-6Al-4V was evaluated. Key process measures were cutting force, workpiece temperature, tool wear, burr formation and average surface roughness (Ra). Experimental results showed that nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. A stand-off distance of 55 and 75 mm is also necessary to control burr formation, workpiece temperature and Ra, but coherent nozzle orientation has no statistically significant impact on the mean values of cutting force and tool wear. It can be concluded that stand-off distance is more substantially significant than nozzle angles when step shoulder milling Ti-6Al- 4V using vegetable oil-based cutting fluid.
Abstract: The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.
Abstract: Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.
Abstract: Ni alloys have managed to cover wide range of applications such as automotive industries, oil gas industries, and aerospace industries. However, these alloys impose challenges while using conventional machining technologies. On the other hand, Micro-Electro-Discharge machining (micro-EDM) is a non-conventional machining method that uses controlled sparks energy to remove material irrespective of the materials hardness. There has been always a huge interest from the industries for developing optimum methodology and parameters in order to enhance the productivity of micro-EDM in terms of reducing machining time and tool wear for different alloys. Therefore, the aims of this study are to investigate the effects of the micro-EDM process parameters, in order to find their optimal values. The input process parameters include voltage, capacitance, and electrode rotational speed, whereas the output parameters considered are machining time, entrance diameter of hole, overcut, tool wear, and crater size. The surface morphology and element characterization are also investigated with the use of SEM and EDX analysis. The experimental result indicates the reduction of machining time with the increment of discharge energy. Discharge energy also contributes to the enlargement of entrance diameter as well as overcut. In addition, tool wears show reduction with the increase of discharge energy. Moreover, crater size is found to be increased in size along with the increment of discharge energy.
Abstract: Noteworthy results have been obtained in the turning and drilling of hardened high-strength steels using tungsten carbide based cutting tools. In a finish turning process, it was seen that surface roughness and tool flank wear followed very different trends against cutting time. The suggested explanation for this behaviour is that the profile cut into the workpiece surface is determined by the tool’s cutting edge profile. It is shown that the profile appearing on the cut surface changes rapidly over time, so the profile of the tool cutting edge should also be changing rapidly. Workpiece material adhered onto the cutting tool, which is also known as a built-up edge, is a phenomenon which could explain the observations made. In terms of tool damage modes, workpiece material adhesion is believed to have contributed to tool wear in examples provided from finish turning, thread turning and drilling. Additionally, evidence of tool fracture and tool abrasion were recorded.
Abstract: Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.
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: Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.
Abstract: Electric discharge machining (EDM) is one of the most widely used non-conventional manufacturing process to shape difficult-to-cut materials. The process yield, in terms of material removal rate, surface roughness and tool wear rate, of EDM may considerably be improved by selecting the optimal combination(s) of process parameters. This paper employs Multi-response signal-to-noise (MRSN) ratio technique to find the optimal combination(s) of the process parameters during EDM of Inconel 718. Three cases v.i.z. high cutting efficiency, high surface finish, and normal machining have been taken and the optimal combinations of input parameters have been obtained for each case. Analysis of variance (ANOVA) has been employed to find the dominant parameter(s) in all three cases. The experimental verification of the obtained results has also been made. MRSN ratio technique found to be a simple and effective multi-objective optimization technique.
Abstract: Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.
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: During machining process, chatter is an unavoidable
phenomenon. Boring bars possess the cantilever shape and due to
this, it is subjected to chatter. The adverse effect of chatter includes
the increase in temperature which will leads to excess tool wear. To
overcome these problems, in this investigation, Cartridge brass (Cu –
70% and Zn – 30%) is passively fixed on the boring bar and also
clearance is provided in order to reduce the displacement, tool wear
and cutting temperature. A conventional all geared lathe is attached
with vibrometer and pyrometer is used to measure the displacement
and temperature. The influence of input parameters such as cutting
speed, depth of cut and clearance on temperature, tool wear and
displacement are investigated for various cutting conditions. From
the result, the optimum conditions to obtain better damping in boring
process for chatter reduction is identified.
Abstract: In this study, to clarify the effectiveness of an
aluminum/chromium/tungsten-based-coated tool for cutting sintered
steel, tool wear was experimentally investigated. The sintered steel
was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and
(Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the
physical vapor deposition (PVD) method. Moreover, the tool wear of
the aluminum/chromium/tungsten-based-coated item was compared
with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool
wear mechanism of the aluminum/chromium/tungsten-coating film for
cutting sintered steel, Scanning Electron Microscope observation and
Energy Dispersive x-ray Spectroscopy mapping analysis were
conducted on the abraded surface. The following results were
obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated
tool was the slowest among that of the five coated tools. (2) Adding
carbon (C) to the aluminum/chromium/tungsten-based-coating film
was effective for improving the wear-resistance. (3) The main wear
mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)-
and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.
Abstract: Haynes 25 alloy (also known as L-605 alloy) is cobalt
based super alloy which has widely applications such as aerospace
industry, turbine and furnace parts, power generators and heat
exchangers and petroleum refining components due to its excellent
characteristics. However, the workability of this alloy is more
difficult compared to normal steels or even stainless. In present work,
an experimental investigation was performed under cryogenic
cooling to determine cutting tool wear patterns and obtain optimal
cutting parameters in turning of cobalt based superalloy Haynes 25.
In experiments, uncoated carbide tool was used and cutting speed (V)
and feed rate (f) were considered as test parameters. Tool wear
(VBmax) were measured for process performance indicators.
Analysis of variance (ANOVA) was performed to determine the
importance of machining parameters.
Abstract: Water miscible cutting fluids are conventionally used to lubricate and cool the machining zone. But issues related to health hazards, maintenance and disposal costs have limited their usage, leading to application of Minimum Quantity Lubrication (MQL). To increase the effectiveness of MQL, nanocutting fluids are proposed. In the present work, water miscible nanographite cutting fluids of varying concentration are applied at cutting zone by two systems A and B. System A utilizes high pressure air and supplies cutting fluid at a flow rate of 1ml/min. System B uses low pressure air and supplies cutting fluid at a flow rate of 5ml/min. Their performance in machining is evaluated by measuring cutting temperatures, tool wear, cutting forces and surface roughness and compared with dry machining and flood machining. Application of nanocutting fluid using both systems showed better performance than dry machining. Cutting temperatures and cutting forces obtained by both techniques are more than flood machining. But tool wear and surface roughness showed improvement compared to flood machining. Economic analysis has been carried out in all the cases to decide the applicability of the techniques.
Abstract: In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation.
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: The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.
Abstract: This paper reports the optimal process conditions for machining of three different types of MMC’s 65vol%SiC/A356.2; 10vol%SiC-5vol%quartz/Al and 30vol%SiC/A359 using PMEDM process. MRR, TWR, SR and surface integrity were evaluated after each trial and contributing process parameters were identified. The four responses were then collectively optimized using TOPSIS and optimal process conditions were identified for each type of MMC. The density of reinforced particles shields the matrix material from spark energy hence the high MRR and SR was observed with lowest reinforced particle. TWR was highest with Cu-Gr electrode due to disintegration of the weakly bonded particles in the composite electrode. Each workpiece was examined for surface integrity and ranked as per severity of surface defects observed and their rankings were used for arriving at the most optimal process settings for each workpiece.