Cutting Parameter Optimization when Machining Different Materials (original) (raw)
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In this study, it is aimed to investigate the surface roughness of cutting tools during the machining of AISI 304 stainless steels, the life of cutting tools and the cutting forces that occur during cutting and machining. The main features of stainless steels are: high corrosion resistance, ductility and high tensile strength. Stainless steels contain elements such as chromium, nickel and molybdenum which affect the machinability in the negative direction; therefore it is very difficult to process stainless steels. This work was carried out using covered cutting tools. The work was carried out at different cutting depths and different feed rates without the use of cooling liquid. The life and wear mechanisms of cutting tools, cutting forces and surface roughness were investigated in relation to cutting parameters.
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.
The assessment of cutting tool wear
International Journal of Machine Tools and Manufacture, 2004
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. This paper argues that the existing criteria of flank wear are insufficient for its proper characterization. Their existence is due to the lack of knowledge on the contact conditions at the tool flank-workpiece interface. Known attempts to evaluate the physical processes at this interface do not help to resolve this issue. This paper compares different characteristics of the evaluation of flank wear. The contact process at the mentioned interface is analyzed through the experimental assessment of the contact stresses, and the full validity of Makarow's law is confirmed, i.e. minimum tool wear occurs at the optimum cutting speed. A new concept of tool resources is proposed and discussed. This resource is defined as the limiting amount of energy that can be transmitted through the cutting wedge until it fails.
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.
Purpose: of the study was to test the applicability of different cutting tools in producing tool-making equipment and to put the emphasis on the mechanisms present in the high-speed-cutting process. Design/methodology/approach: used are optical and SEM observation and comparative analysis of wear types at the cutting edges of the end-mill cutters. Findings: the characteristic wear of end-mill cutters is caused by of the fact that the cutting speed is no longer the main influential factor on wear, but more likely wear is the consequence of the high-speed of the tool movements (feed rate), the tool is worn out when it can no longer generate a prescribed surface quality or assure required workpiece accuracy. Research limitations/implications: all observed parameters, which are difficult to predict, are closely connected with the appearance of favourable wear at the tool tip of the end mill cutter. Practical implications: results presented were also confirmed in the production environment, when dies were produced for practical use. Originality/value: is in description of tool life in HSC, which is related to the tool wear pattern, chip shape and -particularly in advanced machining operations -the surface texture and workpiece accuracy. Optimisation of the cutting parameters in HSC is thus not made with respect to the maximum removal rate, but rather to the low level of the cutting forces and better surface quality.
Optimization of Cutting Parameters of Tool Wear in Turning Operations: A Review
2021
Tool wear is one of the major factors that contribute to surface quality, productivity and accuracy in machining. It also determines production flow by increasing the number of shutdowns for tools reshaping. Tool wear is related to cutting process parameters (depth of cut, spindle speed and feed rate), the surface nature of the metal (scaly or smooth), the cutting forces and thermal condition at cutting zone. This paper present review of various works on optimizing the tool wear rate during turning operation. Also, it presents techniques used in monitoring the processes and methods of determining the rate of tool wear with their results in an orthogonal machining operation on different type of materials.
Cutting force and wear evaluation
Co-cemented tungsten carbide (WC-Co) tools are currently employed in dental application for prosthesis fabrication. The deposition of a diamond coating onto WC-Co tools could allow both to increase the tool life and tool performance at higher speeds. However, at present it is very difficult to quantify the effective advantage of the application of a diamond coating onto dental tools compared to traditional uncoated tools. Therefore, in this work, we have deposited diamond coatings onto WC-Co dental tools having different geometries by Hot Filament Chemical Vapour Deposition (HFCVD). Prior to deposition, the WC-Co tools were pre-treated in order to roughen the surface and to modify the chemical surface composition. The use of the HFCVD process enabled the deposition of a uniform coating despite the complex geometries of the dental mills. For the first time, in accordance to the knowledge of the authors, we have studied and compared the cutting behaviour of both virgin and diamond-coated dental tools by measuring both wear and cutting force time evolution under milling a very hard Co-Cr-Mo dental alloy. To ensure constant cutting rate (20,000-r.p.m. cutting rate, 0.01-m/min feed rate and 0.5-mm depth of cut), a proper experimental apparatus was used. Three different mill geometries were considered in both coated and uncoated conditions. The results showed that, under the high-speed conditions employed, uncoated tools underwent to catastrophic failure within a few seconds of machining. Diamond-coated tools exhibited much longer tool lives. Lower forces were measured when the coated tool was employed due to the much lower material-mill friction. The best behaviour was observed for coated mills with the presence of a chip-breaker. D
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.
MODELING OF THE EFFECT OF TOOL WEAR ON CUTTING FORCES IN TURNING
Machining is the most widely used and efficient material removal process, and tool wear in machining is usually of great interest in order to improve machining efficiency and effectiveness. Cutting tool wear patterns such as the flank and crater wear and the dead metal zone (DMZ) may induce the cutting tool geometry variation in I have had a good time in Clemson Advanced Manufacturing and System Integration Laboratory. There are lots of fun among me and our group members: Xiaoyu
Effects of the cutting feed, depth of cut, and workpiece (bore) diameter on the tool wear rate
The International Journal of Advanced Manufacturing Technology, 2006
Most published studies on metal cutting regard the cutting speed as having the greatest influence on tool wear and, thus, tool life, while other parameters and characteristics of the cutting process have not attracted as much attention in this respect. This is because of the existence of a number of contradicting results on the influence of the cutting feed, depth of cut, and workpiece (bore) diameter. The present paper discusses the origin of the aforementioned contradicting results. It argues that, when the optimal cutting temperature is considered, the influence of the aforementioned parameters on tool wear becomes clear and straightforward. The obtained results reveal the true influence of the cutting feed, diameter of the workpiece, and diameter of the hole being bored on the tool wear rate. It was also found that the depth of cut does not have a significant influence on the tool wear rate. The obtained results provide methodological help in the experimental assessment and proper reporting of the tool wear rates studied under different cutting conditions.