Performance of diamond tool in machining titanium (original) (raw)
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Cutting Parameters and the Machinability Performance
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Optimizing cutting parameters is very significant to obtain good machined surface and meet engineering specifications. It is also can save energy, reduce waste, save processing time, and increase tool life [1]. Generally, there are four types of cutting parameters normally associated with machining operation, i.e., cutting speed, spindle speed, depth of cut, and feed rate [2-6]. All of these parameters have been identified as the influential factors in determining the surface quality of every machined part. Most of the researchers focused on four cutting parameters during their studies on optimization in composite machining. They are spindle speed, cutting speed, depth of cut, and feed rate [7-9]. In general, the best machined surface quality is being determined by the kind of material being cut, and the size and type of the cutter used, width and depth of cut, method of application, and speed available are factors relating to machinability performance. 2.1.1 Cutting Speed (m/min) The cutting speed expressed in meters per minute (m/min) must not be confused with the spindle speed which is expressed in revolution per minute (rpm). Cutting speed represents the rate of the cutter passed over the surface of the machined part, whereby the spindle speed is obtained by calculating from a selected cutting speed. The cutting speed of a metal may be defined as the speed, in surface feet per minute or linear feet per minute (sf/min or mm/min) that a given tooth (flute) at which the metal may be machined efficiently. When the work is machined on a milling machine, the cutter must be revolved at a specific number of (r/min), depending on its diameter to achieve the proper cutting speed. In workshop practices, the machinist used spindle
Experimental Analysis of the Cutting Process and Chip Formation at High Speed Machining
Le Journal de Physique IV, 1997
RCum6. Un nouveau dispositif experimental a ete conqu, permenant de reproduire la coupe orrhogonale a grande vitesse. I1 est ainsi possible d'etudier les effets d'une grande vitesse de coupe sur la fragmentation du copeau et sur les efforts de coupe. Ces grandes vitesses de coupe sont obtenues grice a un canon a gaz qui propuise I'eprouvette, a une vitesse tres superieure a celle obtenue avec des machines conventionnelles (environ 100 mls). Des observations microscopiques des copeaux et une classification systernatique ont permis d'affiner I'analyse des effets de I'augmentation de la vitesse de coupe et des differentes conditions de coupe.
Improving Cutting Tool Life a Review
2013
The cutting tool is an important basic tool required in the machining process of a part in production. It not only performs the cutting action but helps in getting required surface finish and accuracy of the part. In order to perform these tasks the tool has to be strong enough to withstand wear resistance and serve for long period of time to produce more number of components with the same accuracy. Machining is important in metal manufacturing process to achieve near-net shape, good dimensional accuracy and for aesthetic requirements. In modern machining process and using the CNC machine tools the cutting tool will play a vital role in machining process and in improving the surface finish. Many reputed cutting tool manufacturing organizations globally with their rich experience of research and development, invented different ways of enhancing the life of cutting tool in order to optimise the rate of the production and to reduce the cost of production, which is highly acceptable to ...
Materials Today: Proceedings, 2020
Ti-6Al-4V Extra Low Interstitial (ELI) possesses superior properties like higher strength to weigh ratio, better corrosion resistance, good fracture toughness etc., because of controlled interstitial element of iron and oxygen. The effects of four cutting parameters namely cutting speed, feed, depth of cut and tool nose radius on responses like cutting temperature, surface roughness and cutting force have been investigated for turning of Ti-6Al-4V (ELI). Total 81 experiments have been performed in dry environment. Mathematical models for cutting temperature, surface roughness and cutting force have been developed from experimental data using Response Surface Methodology. ANOVA test also has been carried out to evaluate contribution of parameters. The developed model is interfaced with Particle Swarm Optimization to minimize responses. The prediction of cutting force by PSO states that minimum cutting force of 7.419 kgf at cutting speed of 315 rpm, feed of 0.0510 mm/rev, depth of cut of 0.5mm and nose radius of 0.4mm. The prediction of surface roughness by PSO states that minimum surface roughness of 0.328µm at cutting speed of 140 rpm, feed of 0.0510 mm/rev, depth of cut of 0.7mm and nose radius of 1.2 mm. Also the minimum cutting temperature has been predicted by PSO as 31.96 0 C at cutting speed of 140 rpm, feed of 0.0510 mm/rev, depth of cut of 1mm and nose radius of 0.8mm. The confirmation experiments have also been carried out which have measured minimum cutting force of 7 kgf, minimum surface roughness as 0.35µm and cutting temperature of 30 0 C.
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
MATEC Web of Conferences, 2018
In turning process, the cutting tool is essential for shaping materials. The cutting tools with various perforated surfaces help to increase the cutting tool life. Also, advances in CNC machining technologies have enhanced the productivity of machining process. One of the best or futuristic approaches in modern manufacturing engineering is the use of FEM Simulation for the metal cutting process. FEM simulation helps in understanding the metal deformation process and also helps in the reduction of experiments. The simulation helps the researchers to predict the major influencing cutting variable values without carrying out any experiment which is time-consuming and expensive. This research presents the simulation study of the performance of micro-hole patterned Polycrystalline Diamond cutting insert in machining Titanium alloy (Ti-6Al-4V). Micro-holes are drilled using Electrical Discharge Wire Drilling machine on the rake face of Polycrystalline Diamond (PCD) cutting inserts. FEM an...
Parameters That Effect Diamond Wire Cutting Process
International Journal for Research in Applied Science and Engineering Technology, 2017
In today's decorative stone industry wire saws are frequently used due to flexibility, low vibration and noise characteristics with high precision The main problem in practice, wire cutting machine; the life of the rope and breaking with the inability of the time foreseen.A stone cutting machine which is composed of steel rope, cutting tool and drive pulley; mechanism natural frequency was examined by different design parameters. The forced vibration character trying to determine to occur by cutting tool contact with the stone, the dynamic loads from the driving the ropes have been identified. Cutting speed and cutting force In performed analysis is considered as the basic design criteria. Thus, the rope-cutter mechanism design parameters selection, which will improve the of cutting conditions and are working in the direction to increase the operating life.
PERFORMANCE ASSESSMENT OF CUTTING TOOLS – A REVIEW
IAEME Publications, 2020
The aim of this study is to provide an overview of the various methods for evaluating cutting tool efficiency specifically for the turning operation. The cutting operation variables like cutting speed, feed rate and depth of cut have to be elected cautiously during the turning operation to increase profitability by increasing efficiency and lowering overall manufacturing costs for each part. High vibration causes poor surface finish, lower efficiency, and shorter tool life; as a result, this parameter should be kept under control.
2013
This research work focuses on precision turning of Ti6Al4V material to investigate the machinability of the material. Precision turning is a type of machining where, very low feed rate and depth of cut is being used to machine using a cutting insert with a lower nose radius. The cutting parameters considered for the experiments include the cutting speed, feed rate, depth of cut and nose radius. PVD coated carbide cutting inserts with different nose radius and constant rake and clearance angle are being considered for experimentation. The experimentation was designed based on Taguchi's L 27 orthogonal array. Three different levels of cutting parameters were being considered for the experimentation. The turning experiments were carried out on a conventional variable speed motor lathe under dry working conditions. Based upon the experimental values, Analysis of Variance (ANOVA) was conducted to understand the influence of various cutting parameters on cutting force, surface roughness chip morphology, tool wear and cutting tool temperatures during precision turning of titanium alloy. Optimal levels of parameters were identified using grey relational analysis and significant parameter was determined by analysis of variance. Experimental results indicate that multi-response characteristics.