An experimental investigation of hot-machining to predict tool life (original) (raw)
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A study of effects of machining parameters on tool life
This work involves the investigation carried out to study the effects of machining parameters on tool life under dry machining environment. Three cutting tool materials (HSS blank tool-M2 C66, tungsten carbide insert tool grade P-10, DMNG carbide insert tool 150412-SA) and work materials (medium carbon steel 0.4 wt% C, mild steel 0.29 wt% C, brass C330) were examined. The experiments were conducted under three different spindle speeds (900, 1120, 1400rev/min); feed rates (0.1, 0.2, 0.3mm/rev) and depths of cut (0.5, 1.0, 1.5mm). The settings of machining parameters were determined by using the Taguchi experimental design method. The level of importance of the machining parameters on tool life was determined by using analysis of variance (ANOVA). The optimum machining parameters combination was obtained by using the analysis of signal-to-noise (S/N) ratio. The relationship between cutting parameters and tool life was obtained. From the results, the spindle speed had the most significant effects on tool life followed by feed rate and the depth of cut. The life of the HSS when cutting the three work pieces (medium carbon steel, mild steel and brass) was 161s, 321s and 386s respectively. The life of tungsten carbide when cutting the three work materials was 480s, 726s and 1028s respectively. The life of DMNG carbide were 782s using medium carbon steel, 864s using mild steel, and 1183s using brass. The shortest life of the three cutting tool materials (HSS, tungsten carbide and DMNG carbide) on the three work material (medium carbon steel, mild steel and brass) occurred at cutting speed (1400 rev/min), feed rate (0.3 mm/rev) and depth of cut (1.5 mm), where the life of the HSS were (15s using medium carbon steel, 58s using mild steel, 94s using brass). The life of tungsten carbide were (135s using medium carbon steel, 180s using mild steel, 274s using brass) and the life of DMNG carbide were (219s using medium carbon steel, 215s using mild steel, 311s using brass). The increment of spindle speed, feed rate and depth of cut value mostly will affect the tool life.
Study of Effects of Machining Parameters on Tool Life
This work involves the investigation carried out to study the effects of machining parameters on tool life under dry machining environment. Three cutting tool materials (HSS blank tool -M2 C66, tungsten carbide insert tool grade P-10, DMNG carbide insert tool 150412-SA) and work materials (medium carbon steel 0.4 wt% C, mild steel 0.29 wt% C, brass C330) were examined. The experiments were conducted under three different spindle speeds (900, 1120, 1400rev/min); feed rates (0.1, 0.2, 0.3mm/rev) and depths of cut (0.5, 1.0, 1.5mm). The settings of machining parameters were determined by using the Taguchi experimental design method. The level of importance of the machining parameters on tool life was determined by using analysis of variance (ANOVA). The optimum machining parameters combination was obtained by using the analysis of signal-to-noise (S/N) ratio. The relationship between cutting parameters and tool life was obtained. From the results, the spindle speed had the most significant effects on tool life followed by feed rate and the depth of cut. The life of the HSS when cutting the three work pieces (medium carbon steel, mild steel and brass) was 161s, 321s and 386s respectively. The life of tungsten carbide when cutting the three work materials was 480s, 726s and 1028s respectively. The life of DMNG carbide were 782s using medium carbon steel, 864s using mild steel, and 1183s using brass. The shortest life of the three cutting tool materials (HSS, tungsten carbide and DMNG carbide) on the three work material (medium carbon steel, mild steel and brass) occurred at cutting speed (1400 rev/min), feed rate (0.3 mm/rev) and depth of cut (1.5 mm), where the life of the HSS were (15s using medium carbon steel, 58s using mild steel, 94s using brass). The life of tungsten carbide were (135s using medium carbon steel, 180s using mild steel, 274s using brass) and the life of DMNG carbide were (219s using medium carbon steel, 215s using mild steel, 311s using brass). The increment of spindle speed, feed rate and depth of cut value mostly will affect the tool life.
Effect of machining variables on tool life
This work involves the investigation carried out to study the effects of machining parameters on tool life under dry machining environment. Three cutting tool materials (HSS blank tool -M2 C66, tungsten carbide insert tool grade P-10, DMNG carbide insert tool 150412-SA) and work materials (medium carbon steel 0.4 wt% C, mild steel 0.29 wt% C, brass C330) were examined. The experiments were conducted under three different spindle speeds (900, 1120, 1400rev/min); feed rates (0.1, 0.2, 0.3mm/rev) and depths of cut (0.5, 1.0, 1.5mm). The settings of machining parameters were determined by using the Taguchi experimental design method. The level of importance of the machining parameters on tool life was determined by using analysis of variance (ANOVA). The optimum machining parameters combination was obtained by using the analysis of signal-to-noise (S/N) ratio. The relationship between cutting parameters and tool life was obtained. From the results, the spindle speed had the most significant effects on tool life followed by feed rate and the depth of cut. The life of the HSS when cutting the three work pieces (medium carbon steel, mild steel and brass) was 161s, 321s and 386s respectively. The life of tungsten carbide when cutting the three work materials was 480s, 726s and 1028s respectively. The life of DMNG carbide were 782s using medium carbon steel, 864s using mild steel, and 1183s using brass. The shortest life of the three cutting tool materials (HSS, tungsten carbide and DMNG carbide) on the three work material (medium carbon steel, mild steel and brass) occurred at cutting speed (1400 rev/min), feed rate (0.3 mm/rev) and depth of cut (1.5 mm), where the life of the HSS were (15s using medium carbon steel, 58s using mild steel, 94s using brass). The life of tungsten carbide were (135s using medium carbon steel, 180s using mild steel, 274s using brass) and the life of DMNG carbide were (219s using medium carbon steel, 215s using mild steel, 311s using brass). The increment of spindle speed, feed rate and depth of cut value mostly will affect the tool life.
Journal of materials processing technology, 2002
In this study, the high manganese steel specimens heated with liquid petroleum gas flame were machined on a lathe under different cutting conditions of feed rates, depth of cuts, cutting speeds and surface temperatures. A mathematical model for tool life was obtained from the experimental data using a regression analysis method. In addition, the tool life was estimated using artificial neural network (ANN) with backpropagation (BP) algorithm. Then, this program was trained and tested. Finally, the experimental data are compared with both the regression analysis results and the estimations of ANN.
Prediction of Tool Life and Experimental Investigation during Hot Milling of AISI H13 Tool Steel
Advanced Materials Research, 2009
This paper presents the results of experimental investigations conducted on a vertical machining centre (VMC) using spindle speed, feed rate, and depth of cut as machining variables to ascertain the effectiveness of TiAlN insert in end milling of hardened steel AISI H13, under workpiece preheated conditions and hence a statistical model was developed using the capabilities of Response Surface Methodology (RSM) to predict the tool life. Sufficient number of experiments was conducted based on the small central composite design (CCD) concept of RSM to generate tool life data for the selected machining variables. The adequacy of the model was tested at 95% confidence interval. Meanwhile, a time trend was observed in residual values between model predictions and experimental data, reflecting little deviations in tool life prediction. A very good performance of the RSM model, in terms of agreement with experimental data, was achieved. The model can be used for the analysis and prediction of the complex relationship between cutting conditions and the tool life in flat end milling of hardened materials.
IOP Conference Series: Materials Science and Engineering, 2020
Tool life is an important thing to consider in the process of metal cutting. Before the machining process is done, it is necessary to know how long a cutting tool is capable of cutting before wear occurs. However, it is difficult to predict the life of the cutting tool, because each cutting tool has different characteristics in cutting metal. The research was conducted aimed at predicting the life of cutting tool using the Taylor equation, but the n and C constants contained in the equation vary for each type of cutting tool used in cutting workpieces. Through the experiment of cutting metal using a lathe, the cutting tool was observed and measured for wear, so that there was a limit to the value of the wear edge of the VB tool by 0.4 mm. The three cutting speed variants used in the cast iron machining are 180, 210 and 249 m / min. Observations were made every 10 minutes machining was stopped to be measured using a Digital Microscope if the wear value of the cutting tool has not been achieved, then machining continues. The worn cutting tool is no longer used in machining, then uses the new cutting tool. The results of the study showed that the increase in cutting speed had an effect on the wear rate that occurred in the cutting tool. The extended equation for Tool life of Taylor is obtained by Vc. Tl. 0.81 = 5011.87 1. Introduction The metal formation can be done using machine tools, one of which is the turning process. Workpiece materials such as cast iron have strong hard properties but are brittle, therefore we need cutting tools that have a high strength to do the cutting of hard metals. Often to increase the rate of production, the machining parameters used such as cutting speed, depth of cut, the feed rate is increased, this can give effect to the processing time can be shorter, but the effect of tool life is shorter. This is certainly very ineffective in the machining process because the cutting tool will always be replaced so that it creates non-productive time for the replacement of the cutting tools. The wear of cutting tools often occurs when the machining process is carried out to cut hard metals at high speeds, so it is not known how long the cutting tools can perform their functions at a cutting speed used. Therefore, it is necessary to predict cutting tool life when machining with varying cutting speeds. Through the experimental method and the development of tool life equations Taylorequations,this research was carried out to obtain an extended value of Taylor equitation tool life. The aim of this research is to predictive values of tool life cutting tools when the turning of cast iron workpieces so that it is known how long the life of cutting tools are used for various cutting speeds used.
Tool-Life Modelling of Carbide and Ceramic Cutting Tools Using Multi-Linear Regression Analysis
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2006
This paper presents a study for the development of tool-life models for machining operations by means of a statistical approach called multi-linear regression analysis. The study was applied to a milling process for machining SAE 121 cast iron in a factory without interrupting the mass production. Different cutting tool materials under dry conditions were used in the cutting tests. Several machining experiments were performed and mathematical models for tool life have been postulated by using least-square regression analysis. The analysis was based on a first-order model in which the tool life is expressed as a function of two independent variables; cutting speed and feed rate. Analysis of variance was applied to check the adequacy of the mathematical models and their respective parameters. In order to demonstrate the usefulness of the developed models, tool-life contours have been generated and presented in different plots.
An Experimental Investigation of Hot Machining Performance Parameters using Oxy-Acetylene gas setup
2014
This paper focuses on optimizing the cutting conditions for the average surface roughness (Ra) and metal removal rate (MRR) obtained in hot machining of 15-5PH martensitic stainless steel with 40 HRC. Hot machining experiments were performed on lathe machine using K313 carbide tool insert. Experiments were conducted based on Taguchi L18 orthogonal array. The statistical method of signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) were employed to investigate the optimum process parameters like speed feed, depth of cut and workpiece temperature and their effect on the performance characteristics i.e., surface roughness and metal removal rate. The results of the study indicate that feed rate has the most significant effect on surface roughness. Cutting speed and feed rate has the most significant effect on material removal rate.
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit, describes a helix toolpath by moving more or less linearly while the workpiece rotates.Machining of High Carbon High Chromium steel (HCHCr) is a challenge for production engineers in tool industry. In this research paper, a study on turning HCHCr Steel using tungsten carbide tool inserts is made by varying depth of cut, the cutting and feed rate speed one each at a time and keeping other two constant. The effect on process parameters like surface finish, material removal rate, tool wear, Cutting force, thrust force and temperature distribution on tool tip are discussed. Organised by: ATME College of Engineering, Mysuru, INDIA © 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 12
Tool Life Modeling Based on Cutting Parameters and Work Material Hardness in Turning Process
In this paper we have presented methodology for development of life prediction model for first order tool during turning of hardened 42CrMo4 steel at different levels of hardness. It is important to be able to predict and describe the tool life in regards to manufacturing costs during industrial production. Tool life is defined as the of cutting time that tool can be used. Cutting tools can be used when they do not reach tool life criteria and can produce parts with desired surface finish and dimensional accuracy. Flank wear of cutting tools is often selected as the tool life criterion because it determines the diametric accuracy of machining, its stability and reliability. Tool wear is defined as a gradual loss of tool material at contact zones of workpiece and tool material, resulting the cutting tool to reach its life limit. This paper investigates the tool wear of TiN coated tungsten carbide inserts under dry cutting, using the central composite design of experiments method (DoE...