Carbide Tool Inserts Research Articles

Cost-effective way of hard turning with newly developed HSN2-coated tool

ABSTRACTEN-31 (AISI 52100, hardness 55 HRC) is one of the difficult-to-cut steel alloys and it is commonly used in shafts and bearings. Nowadays, it is becoming a challenge to the cutting tool material for economical machining of extremely tough and hard steels. In general, CBN and PCBN tools are used for machining hardened steel. However, machining cost using these tools becomes higher due to high tool cost. For this purpose, carbide tool using selective coatings is the best substitute having comparable tool life, while its cost is approximately one-tenth of CBN tool. In this work, the newly developed second-generation TiAlxN super nitride (i.e., HSN2) is selected for PVD coating on carbide tool insert and further characterized using thermogravimetric analysis and differential scanning calorimetry for oxidation and thermal stability at high temperature. Later, HSN2-coated carbide inserts are successfully tested for their sustainability to expected tool life for turning of AISI 52100 steel. In the present study, forces, surface finish, and tool wear are used as a measure to appraise the performance of hard turning process. Experimentally, it is found that speed, feed rate, and depth of cut have considerable impact on forces, insert wear, and surface roughness of the machined surface.

Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool

Understanding how feed rate (ft) affects tool deterioration during milling of Ni-based superalloys is practically important, but this understanding is currently insufficient. In the present study using a 718Plus Ni-based alloy and cemented tungsten carbide tool inserts, milling experiments were conducted with ft = 0.10 mm/tooth under either dry or wet (with coolant) conditions. The results are compared to those based on using ft = 0.05 mm/tooth from previous studies. The milling force (F) was monitored, the cutting tool edge was examined and the flank wear (VBmax) was measured. As would be expected, an increase in ft increased F. It was found that F correlated well with VBmax for the high ft (0.1 mm/tooth) experiments, as opposed to the previously observed poor F-VBmax relationship for the lower ft (0.05 mm/tooth) value. This is explained, supported by detailed failure analysis of the cutting tool edges, by the deterioration mode to be dominantly edge chipping with a low occurrence of fracturing along the flank face when the high ft was used. This dominancy of the deterioration mode means that the tool edge and workpiece contact was consistent and thus resulted in a clear F-VBmax relationship. A clear F-VBmax relationship should then mean monitoring VBmax through monitoring F is possible.

Effect of surface hardness and roughness produced by turning on the torsion mechanical properties of annealed AISI 1020 steel

This paper presents the results of experimental work carried out to study the influence of surface integrity, measured as hardness (HV) and roughness (Ra) on torsional properties of annealed AISI 1020 steel machined by turning using carbide insert tools. The results showed a reduction in ductility when hardness and roughness increase, caused by the plastic deformation induced after machining. It was shown that the shear yield strength increases, as a consequence of the material strengthening by work-hardening and the rise of stress concentrators. Further, the ultimate shear strength increases with surface hardness, having the opposite effect when the surface roughness caused greater stress concentration.

Assignment of weightage to machining characteristics to improve overall performance of machining using GTMA and utility concept

In an automated manufacturing system, performance of machining is an important characteristic that affects the production cost especially in machining processes like milling and boring. Boring is one of critical machining processes, and therefore, it is very difficult to determine overall performance of the process. In the present work, an attempt was made to maximize overall performance of the process in order to reduce reworking and production cost. Three different performance characteristics like surface roughness, tool wear and root mean square of workpiece vibration velocity are considered to determine overall performance for boring of AISI 1040 steel with carbide tool inserts. According to User's Preference Rating, weights for the three performance characteristics are calculated using graph theory and matrix approach (GTMA). Overall performance or utility value of the machining process is calculated using utility concept. A response surface methodology (RSM) is used to optimize the process parameters for maximization of performance of the process. Weights of surface roughness, tool wear and root mean square of workpiece vibration velocity are calculated as 0.489, 0.367 and 0.184 respectively. Optimum process parameters were found to be 0.4mm of nose radius, 170m/min of cutting speed and 0.1358mm/rev of feed rate.

PROPERTIES AND CUTTING PERFORMANCE OF TiAlSiN COATING PREPARED BY CATHODE ARC ION PLATING

TiAlSiN coating was deposited on high-speed steel (HSS) samples and cemented carbide tool inserts, respectively, by a new coating preparation procedure, and its properties and cutting performance were characterized. The coating thickness, chemical composition, microstructure morphology and mechanical properties were investigated by X-ray fluorescence measurement system, energy dispersive spectrometer (EDS), scanning electron microscope (SEM), nanoindentation, Rockwell hardness tester and ball-on-disc tribometer. A 3D orthogonal cutting experiment model was established by DEFORM-3D to study the influences of different coating thicknesses on cutting force and temperature, and the field cutting experiment was carried out. The results show that the thickness of TiAlSiN coating is 3.14[Formula: see text][Formula: see text]m prepared by the 3[Formula: see text][Formula: see text]m preparation procedure, microhardness is 36.727[Formula: see text]GPa with the Si content of about 5.22[Formula: see text]at.% as well as good fracture toughness and adhesion strength. The TC4 and AISI 1045 cutting tool inserts with 4[Formula: see text][Formula: see text]m coating thickness have the minimum cutting forces of about 734.7[Formula: see text]N and 450.7[Formula: see text]N, respectively. Besides, tool inserts with a thickness of 3[Formula: see text][Formula: see text]m have the minimum cutting temperatures of about 510.2[Formula: see text]C and 230.6[Formula: see text]C, respectively.

Chip Formation in the Machining of Al-Si/10% AlN Metal Matrix Composite by using a TiN-coated Carbide Tool

This paper presents a study on chip formation in the milling process of Al-Si/10% AlN Metal Matrix Composite (MMC). It focuses on the effect of cutting parameters on the formation of the chip. Al-Si/10% AlN MMC reinforced with 10% AlN particle is a new-generation material that is suitable for manufacturing automotive and aerospace components. Several advantageous characteristics of this material include low density, light weight, high strength, high hardness and high stiffness. The milling process was carried out at dry cutting conditions by using TiN-coated carbide tool insert, which was developed by Standards and Industrial Research Institute of Malaysia (SIRIM). The machining parameters were as follows: a constant cutting speed of 230 m/min, feed rates of 0.4, 0.6 and 0.8 mm/tooth and cutting depths of 0.3, 0.4 and 0.5 mm. The analysis of the chip formation was performed using a video microscope (Sometech, SV-35). The chips were formed because of the shear between the work pieces and the cutting chips during dry milling of Al-Si/10% AlN MMC. These chips were small, short and discontinuous with outer face cracks.

Effect of CNC Lathe Machining Performance by Varying Coolant Nozzle Diameter

Background/Objectives: The cutting temperature is important in machining process. The temperature is a most common effect base on cutting parameters such as cutting speed, feed rate and depth of cut. Optimization of the cutting parameter can also reduce of heat temperature. This way can reduce cost and also can produce a good quality of production. Method/Statistical Analysis: In this study focus on effect of machining the aluminum alloy AL6061 by using a various diameter coolant nozzle during CNC lathe process of its inherent advantages. Hence, it also studies the effect of cutting temperature to the surface roughness and dimensional error that will be considered with the parameters to arrive at a conclusive result. Taguchi method orthogonal array L16’ was selected as an experimental plan for turning on AL6061 by using CNC PUMA 230 turner with carbide tool insert. The L16’ array used 5 factors and 4 levels in conduct the temperature measurement. Findings: Results show that the dominant failure mode is the surface roughness and dimensional accuracy when the nozzle orifice size increases during machining of aluminum alloy AL6061. The exploration for dimensional accuracy, productivity and the optimization of cutting speed in the technical and commercial aspects of the manufacturing processes of aluminum AL6061 are discussed in oil and gas components industries for further work. Applications/Improvements: Conclusion and recommendations will suggest an enhancement to this application.

Progression of tool deterioration and related cutting force during milling of 718Plus superalloy using cemented tungsten carbide tools

Understanding how tool deterioration affects total force (F) during milling of Ni-based superalloys is important for the improvement of machinability of the alloys and serves to clarify whether and how an F-based method for monitoring tool deterioration is possible. In this study, a series of milling experiments have been conducted on 718Plus Ni-based alloy using cemented tungsten carbide tool inserts. F was monitored, and the conventional flank wear (VBmax) to represent insert deterioration was measured. As would be expected, the general trend of how F increased as the number of milling pass (Npass) increased agreed with the general trend of increasing VBmax as Npass increased. But the F-VBmax plot has shown a rather poor F-VBmax relationship. This was the results of the different modes of tool deterioration affecting VBmax differently, but VBmax did not represent fully the true cutting edge of the deteriorating tool insert. Chipping and breakage of the inserts confined in the cutting edge area, resulting in the significant blunting of the edge, caused a high rate of F increase as VBmax increased. Fracturing along the flank face of thin pieces effectively increased VBmax without increasing the cutting edge area and without further blunting the edge, thus no increase in F was required. That the high rate, meaning high ΔF/ΔVBmax, results from the effect of edge deterioration/blunting on reducing the effective rake angle and thus increasing F is suggested and discussed.

Optimizing Multi Characterstics in Machining of AISI 4340 Steel Using Taguchi’s Approach and Utility Concept

This paper aims to develop the multi response optimization technique for predict and select the optimal setting of machining parameters while machining AISI 4340 steel using utility concept. The experimental studies in machining were carried out under varying conditions of process parameters, such as cutting speed (v), feed (f) and different cooling conditions (i.e. dry, wet and cryogenic in which liquid nitrogen used as a coolant) by using uncoated tungsten carbide insert tool. Experiments were carried out as per Taguchi’s L9 orthogonal array with the utility concept and multi response optimization were performed for minimization of specific cutting force (K S ) and surface roughness (R a ). Further statistical analysis of variation (ANOVA) and analysis of mean (ANOM) were used to determine the effect of process parameters on responses K S and R a based on their P value and F value at 95 % confidence level. The optimization results proved that, cutting speed 57 m/min, feed 0.248 mm/min and cryogenic cooling is required for minimizes K S and R a .

Influence of cutting fluid conditions and cutting parameters on surface roughness and tool wear in turning process using Taguchi method

In this experimental work, the effect of various cutting fluid levels and cutting parameters on surface roughness and tool wear was studied. Taguchi orthogonal array was employed to minimize the number of experiments. The experiments were carried out on mild steel bar using a TiCN+Al2O3+TiN coated carbide tool insert in the CNC turning process. The effect of feed rate was found to be the dominant factor contributing 34.3% to surface roughness of the work-piece. The flow rate of the cutting fluid also showed a significant contribution (33.1%). However, cutting speed and depth of cut showed little contribution to surface roughness. On the other hand, cutting speed (43.1%) and depth of cut (35.8%) were the dominant factors influencing tool wear. However, application of cutting fluid (13.7%) showed a considerable contribution, while the feed rate gave the least contribution to tool wear. The optimum cutting conditions for desired surface roughness and tool wear were at a high level of cutting speed, medium level of depth of cut, low level of feed rate and low-flow high-velocity (LFHV) cutting fluid flow from the selected levels.

Experimental study of tool life transition and wear monitoring in turning operation using a hybrid method based on wavelet multi-resolution analysis and empirical mode decomposition

This paper deals with the experimental study of the tool life transition and the wear monitoring during the turning operation of AISI D3 steel workpiece using coated carbide tool inserts (TiCN/Al2O3/TiN). A hybrid method, based on the combination of wavelet multi-resolution analysis (WMRA) and Empirical Mode Decomposition (EMD), is proposed to analyze vibratory signals acquired during the machining process. Using the mean power and the energy as main scalar indicators, the proposed method has been optimized and evaluated in several configurations including the cutting speed, the feed rate, and the depth of cut. The results show that the proposed hybrid method (WMRA/EMD) gives better evaluation of the tool state and the wear monitoring compared to the application of WMRA or EMD alone.

Achievement of Ductile Regime Machining in High Speed End Milling of Soda Lime Glass by Using Tungsten Carbide Tool Insert

Soda lime glass is widely used in optics, chemical apparatus, camera lens, micro gas turbines, light bulbs etc. on account of its high hardness, corrosion resistance, and excellent optical properties. These require high dimensional accuracy and flawless surface finish. However, soda lime glass is inherently brittle leading to subsurface crack propagation and fracture which compromise its functionality. To avoid these defects, the machining needs to be performed under ductile mode conditions. Therefore, this research investigates the viability and requisite conditions for achieving ductile regime machining (DRM) in high speed micro-end milling of soda lime glass. Machining was performed at high cutting speeds (30,000 to 50,000 rpm), feed rate (5 to 15 mm/min), and depth of cut (3 to 7 μm). A surface profilometer was then used to measure the surface roughness and a scanning electron microscope (SEM) used to scrutinize the resultant machined surfaces. The results demonstrate that ductile streaks and rounded gummy chips (without sharp or jagged edges) are produced in all runs. In addition, there are no subsurface cracks and the minimum surface roughness attained is 0.08μm. These indicate that DRM of soda lime glass is obtainable using high-speed micro end milling in a conventional end mill with tungsten carbide inserts.

Experimental Investigation and Analysis of Cutting Forces When Machining X5CrNi18-10 Stainless Steel

In this study, cutting forces experimental measurement an analysis with special carbide insert when turning austenitic stainless steel have been investigated. Stainless steel X5CrNi18-10 is often considered as poorly machinable material. In this experimental study a number of turning tests carried out by using a test lathe and a cutting force measuring device are presented. Accordingly the effect of cutting speed and tool insert cutting geometry on cutting forces in turning austenitic stainless steel X5CrNi18-10 (AISI 304) using Wiper cemented carbide tool insert has been discussed. The effect of cutting parameters (feed rate, depth of cut) is also analyzed by cutting forces measurement. The input parameters were varied as vc = 100 m.min-1, f = 0,150 and 0,275 mm and edge geometry r = 95°, r'= 5°, εr = 80°, rε = 0, 8 mm, s = -6°. The results show that main cutting force Fc decreases with the increasing of cutting speed in turning without using the coolant. A benefit for production process also confirmed fact that this growth is 2,5 to 3 times higher as for turning of CS0E4 under the same machining conditions due to the hardening of austenitic steels for chip creation. It was also noted that experimental specimens showing larger cutting forces then generated worse surface finish as well as larger surface damage.

Experimental study on tool condition monitoring in boring of AISI 316 stainless steel

In this article, effect of cutting parameters, namely, cutting speed, feed rate and tool nose radius, on the tool life was examined experimentally. The experiments were performed on boring of AISI 316 steel with cemented carbide tool inserts. Design of experiments was prepared, and eight experiments were performed with two levels of the cutting parameters. The effects of cutting parameters were analyzed by evaluating the amplitude of workpiece vibration, surface roughness and volume of metal removed. The experimental data were taken for evaluation of tool life for a flank wear of 0.6 mm in all the eight trials. A laser Doppler vibrometer was used for online data acquisition of workpiece vibration, and a high-speed fast Fourier transform analyzer was used to process the acousto-optic emission signals for the workpiece vibration. Taguchi, analysis of variance and regression analysis methods were used to identify significant cutting parameters affecting the workpiece vibrations, surface roughness and volume of metal removed. All selected analysis methods used in this study predicted similar cutting parameter.

Modelling and Optimization of Tool Wear in Machining of EN24 Steel Using Taguchi Approach

This paper presents the effects of process parameters like cutting speed, feed rate and different cooling conditions (i.e. dry, wet and liquid nitrogen used as a coolant) on tool wear (crater and flank wear) in machining of EN24 alloy steel using uncoated tungsten carbide insert tool. Experiments were carried out as per Taguchi’s L9 orthogonal array and further statistical analysis of variation (ANOVA) was used to study the effect of process parameters on responses i.e. crater wear and flank wear, based on their P value and F-value at 95 % confidence level. Overall, cryogenic cooling provides improved tool life leading to extended product life and performance. Mathematical models for crater and flank wear are found to be statistically significant.

Experimental Investigation of Machining AISI 1040 Medium Carbon Steel Under Cryogenic Machining: A Comparison with Dry Machining

This experimental work was carried out by turning of AISI 1040 medium carbon steel in which the effect of cryogenic cooling (LN2) used as a cutting fluid is compared to that of dry machining with respect to tool wear i.e. crater and flank wear, surface roughness, cutting forces (feed and cutting forces) and cutting temperature. Experiments were performed using uncoated tungsten carbide insert tool having various feed rate and constant cutting speed. Compared to dry machining, in LN2 machining, overall the tool wear were reduced to 55.45 and 65.53 %, surface roughness was reduced to 125.90 % and forces were reduced to 61.94 and 96.60 %. The experimental results proved that the application of cryogenic coolant overall increases the machining performance as compared to dry machining.

The Mechanical and Tribology Properties of Sputtered Titanium Aluminum Nitride Coating on the Tungsten Carbide Insert Tool in the Dry Turning of Tool Steel

The Mechanical and Tribology Properties of Sputtered Titanium Aluminum Nitride Coating on the Tungsten Carbide Insert Tool in the Dry Turning of Tool Steel

The Mechanical and Tribology Properties of Sputtered Titanium Aluminum Nitride Coating on the Tungsten Carbide Insert Tool in the Dry Turning of Tool Steel

The effect of the sputtering parameters on the mech anical tribology properties of Titanium Aluminum Nitride coating on the tungsten cabide insert tool in the dry turni ng of tool steel has been investigated. The coating was deposited using a Direct Current magnetron sputtering system with v arious substrate biases (-79 to -221 V) and nitroge n flow rates (30 to 72 sccm). The dry turning test was carried out o n a Computer Numeric Code machine using an optimum cutting parameter setting. The results show that the lowest flank wear (~0.4 mm) was achieved using a Titanium Aluminum Nitride-coated tool that was deposited at a high su bstrate bias (-200 V) and a high nitrogen flow rate (70 sccm). The lowest flank wear was attributed to high coating ha rdness.

Prediction of cutting force in turning process: An experimental and fuzzy approach

This paper presents a comparison of experimental results and a fuzzy rule based system model for calculating the cutting force in the turning operation. A full bridge dynamometer was used to measure the cutting forces over the mild steel work piece and Cemented Carbide Insert tool for different combinations of cutting velocity, feed rate and depth of cut. The rake angle, approach angle and nose radius of the cutting tool insert is kept constant throughout the experiment. This fuzzy model consists of 27 rules and Mamdani Max-min inference mechanism was used. The Taguchi designs of experiments were used to determine the number of experiments. Also, an attempt had been made to analyze the influence of the parameters using the regression analysis which yields a maximum error of 3.214% at the time of prediction which was smaller. The experiments are planned based on Taguchi's design and the measured cutting forces were compared with the predicted forces in order to validate the feasibility of the proposed design. The percentage contribution of each process parameter had been analyzed using Analysis of Variance ANOVA. Experimental results were compared with the regression analysis and predicted fuzzy model. The difference between experimental and predicted results was obtained as around 98.84%.

Application of Response Surface Methodology and Firefly Algorithm for Optimizing Multiple Responses in Turning AISI 1045 Steel

Optimization of machining parameters considering multiple responses flank wear, surface roughness, and material removal rate (MRR) simultaneously are performed using response surface methodology (RSM). The workpiece material chosen for turning is AISI 1045, medium carbon steel, and uncoated carbide tool inserts. Twenty experiments are designed based on face-centered center composite design for three numerical parameters such as cutting speed, feed rate, and depth of cut. In this work, wear at the flank face of the cutting tool insert and surface roughness at the machined surface are to be minimized, whereas the MRR has to be maximized. With the obtained optimum condition, a confirmation experiment is performed and the experimental results obtained are flank wear of 0.118 mm, surface roughness of 3.27 μm, and MRR of 187.35 gm/min, which shows that prediction using RSM is within the acceptable range. Along with the combined optimization of these responses, a quadratic empirical model is generated for each response. An evolutionary optimization algorithm, firefly algorithm, is applied to determine the optimum machining parameters for the chosen objective of lowering flank wear and increasing MRR within a specific surface roughness value.