The Influence of Cutting Edge Radius Size on the Tool Life of Cemented Carbide Drills (original) (raw)
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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.
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.
CIRP Annals - Manufacturing Technology, 2002
The fatigue and wear behaviour of PVD coatings on cemented carbide inserts with various cutting edge radii are investigated experimentally and analytically in milling. The inserts with cutting edge radii from 8 up to 35 µm were manufactured by honing and micro-blasting. The tool wear progress was depicted through Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) microspectral analysis. The Finite Elements Method (FEM) simulation of the contact between the tool and the workpiece highlights the effect of the cutting edge radius on the first coating fracture and the further wear development. The wear behaviour of the cutting edge radii manufactured by honing, in comparison to the corresponding ones by means of micro-blasting, is significantly enhanced, whereas the cutting edge radius increasing can lead to a higher tool life.
The Effect on the Cemented Carbide Cutting Tool of Austempering Process
Transactions of the Indian Institute of Metals, 2014
Austempered ductile irons (ADI) have been developed for an increasing number of the engineering applications such as crankshaft, gears, and other mechanic equipments because of its combination of strength and toughness. Therefore, austempering process has important effects on the mechanical properties of ADI. In this study, we have investigated the effect of austempering process on the cutting tool stresses. The cutting forces (main cutting force, feed force and thrust force) obtained from experimental studies have been applied to rake face, main cutting edge, auxiliary cutting edge on the cutting tool, and then the stresses (von-Mises, shear stress, normal stresses in the X, Y and Z directions) occurred on the cutting tool has been analyzed based on finite element method using ANSYS Workbench commercial software. It is also observed that analytical process of Frocht for the stresses on cutting tool tip. The results obtained show that the austempering process is the significant factor affecting cutting tool stresses.
The influence of drill point geometry on tool life
Tehnički glasnik, 2018
Drilling is a cutting process that uses a rotary cutting tool to cut a cylindrical hole in a solid material. During machining, drill bits are exposed to rapid wear at high temperature. Sometimes, due to an ecological need for dry technology without any lubricant, the use of drill bits with coatings is required, typically titanium nitride (TiN), titanium carbon nitride (TiCN) or titanium aluminium nitride (TiAlN). This paper presents research on drilling done to determine how drill point geometry affects the drill lifetime and finished surface quality. We compared the chip removal ability and surface quality of bored holes in Hardox 500 created with high-speed steel drill bits and drill bits manufactured from hard metals, with and without coatings, under constant processing parameters. A cost/efficiency comparison was also carried out with respect to drill bit fabrication, sharpening, and use. Based on the data obtained on the damage drill points, the most economical drill bit for pr...
Cutting performance of CBN and diamond tools in dry turning of cemented carbide
Mechanical Engineering Journal, 2016
This research deals with the hard turning of cemented carbide with CBN and diamond tools, and focuses on the tool performance, mainly tool wear with respect to cutting force and cutting temperature. The internal turning tests without cutting fluid are executed with the vertical machining center. Seven types of tool materials: SC, CVD-SC, two PCDs, BL-NPD (Binderless nano-polycrystalline diamond) and CBN: are selected for cutting three grades of cemented carbides WC having the different Co binder content (12%, 20% and 25%). Attrition has been found to be the main tool wear mechanism for all tools with slight adhesion of the workpiece binder on the tool face. In cutting of softest carbide WC-m (25% Co), the polycrystalline CBN tool has the lowest tool wear than any other PCD tools. In turning of harder carbides WC-d (20% Co) and WC-t (12% Co), both polycrystalline CBN and PCD cannot be used continuously due to their low hardness, and BL-NPD, SC and CVD-SC tools are applicable. And the BL-NPD tool has the best cutting performance with less flank wear. As for WC-d, extremely stable cutting can be done with BL-NPD where the principal cutting force is kept almost constant at 40 N. Only BL-NPD tool can continue to turn the hardest WC-t. In spite of turning hard materials, the tool temperatures measured are relatively low below 450°C due to the high thermal conductivities of tool materials. However, cutting temperature is directly related to the tool wear and cutting force rather than thermal conductivity of tool in turning of WC-m and WC-t.
Machining of Nickel Based Alloys Using Different Cemented Carbide Tools
Journal of Engineering Science …, 2010
This paper presents the results of experimental work in dry turning of nickel based alloys (Haynes-276) using Deferent tool geometer of cemented carbide tools. The turning tests were conducted at three different cutting speeds (112, 152, 201and 269 m/min) while feed rate and depth of cut were kept constant at 0.2 mm/rev and 1.5 mm, respectively. The tool holders used were SCLCR with insert CCMT-12 and CCLNR-M12-4 with insert CNGN-12. The influence of cutting speed, tool inserts type and workpiece material was investigated on the machined surface roughness. The worn parts of the cutting tools were also examined under scanning electron microscope (SEM). The results showed that cutting speed significantly affected the machined surface finish values in related with the tool insert geometry. Insert type CCMT-12 showed better surface finish for cutting speed to 201 m/min, while insert type CNGN-12 surface roughness increased dramatically with increasing of speed to a limit completely damage of insert geometer beyond 152 m/min.
Wear, 2011
This work shows the resulting height and shape of the burrs produced by drilling holes with ratio L/D = 3. The tool used in the tests was the solid twist HSS drill coated with TiAlN, with diameter of 10 mm, to drill the microalloyed steel DIN 38MnS6. The height of the burr was studied under different lubricant/coolant systems, namely: dry machining, use of Minimum Quantity Lubrication (MQL) at the flow rate of 30 ml/h, and fluid applied in the conventional way (flooding). The following cutting fluids were used: vegetable oil (MQL), mineral oil (MQL and flooding) and semi-synthetic oil (flooding). The trials were carried out at two cutting speeds (45 and 60 m/min) and the criterion adopted for the end of the test was the catastrophic failure of the drill. The results showed that the height of the burr increases primarily with the wear of the tool and that this increase is almost exponential after 64% and 84% of drills life, for the speeds of 45 and 60 m/min, respectively. Furthermore, the results generally showed that the smallest burr height was obtained for the dry machining and the largest for the MQL systems.
EFFECT OF THE CUTTING EDGE SHAPE ON THE PERFORMANCE OF COATED CEMENTED CARBIDED INSERTS
In the present paper, the effect of the coated cutting edge shape on the tool milling performance is described. According to the actual cutting edge profile, three groups of coated cemented carbides inserts with an AlTiN PVD film without treatment (as dep.) as well as with slight (S.G.) or intensive (I.G.) cutting edge rounding were ex- amined. The cutting edge geometry was determined by confocal white light scan- ning, while the film thickness on the tool flank and rake were registered, by micro cratering tests combined with confocal measurements. The impact resistance and corresponding fatigue properties versus the impact temperature were detected by impact tests. The cutting performance of the inserts of the various groups, was in- vestigated in peripheral milling, of hardened steel 42CrMo4 QT. The obtained re- sults were explained by FEM calculations of the material removal process enabling the determination of the developed stresses and temperature distributions in the cut- tin...