Cutting Tool Inserts Research Articles

Analysis of Effects of Machining Parameters on Cutting Force Components in Turning AISI 201 Stainless Steel Using Cemented Carbide Cutting Tool Insert

Abstract The effectiveness of the finished component in turning process is highly reliant on the parameters related to the workpiece and cutting tool. This paper aims to assess the impact of machining parameters on tangential, radial and axial forces while turning AISI 201 stainless steel using cemented carbide tool insert. Process parameters such as spindle speed, feed, depth of cut, and workpiece diameter were used. Four-factors and four-level L16 Taguchi Design of Experiments were employed. In addition, the Analysis of Variance (ANOVA) was used to explore the effects of process parameters and their impact on interactions. After that, an attempt was made to generate prediction models by establishing a regression equation for the cutting forces. Predicted and measured values were plotted in the graphs and comparisons were shown. Finally, the interaction effects between the cutting forces and machining parameters were analyzed as well.

Modeling and Optimization of Cutting Parameters during Machining of Austenitic Stainless Steel AISI304 Using RSM and Desirability Approach

In the current paper, cutting parameters during turning of AISI 304 Austenitic Stainless Steel are studied and optimized using Response Surface Methodology (RSM) and the desirability approach. The cutting tool inserts used in this work were the CVD coated carbide. The cutting speed (vc), the feed rate (f) and the depth of cut (ap) were the main machining parameters considered in this study. The effects of these parameters on the surface roughness (Ra), cutting force (Fc), the specific cutting force (Kc), cutting power (Pc) and the Material Removal Rate (MRR) were analyzed by ANOVA analysis.The results showed that f is the most important parameter that influences Ra with a contribution of 89.69 %, while ap was identified as the most significant parameter (46.46%) influence the Fc followed by f (39.04%). Kc is more influenced by f (38.47%) followed by ap (16.43%) and Vc (7.89%). However, Pc is more influenced by Vc (39.32%) followed by ap (27.50%) and f (23.18%).The Quadratic mathematical models, obtained by the RSM, presenting the evolution of Ra, Fc, Kc and Pc based on (vc, f, and ap) were presented. A comparison between experimental and predicted values presents good agreements with the models found.Optimization of the machining parameters to achieve the maximum MRR and better Ra was carried out by a desirability function. The results showed that the optimal parameters for maximal MRR and best Ra were found as (vc = 350 m/min, f = 0.088 mm/rev, and ap = 0.9 mm).

Effect of Vibration on Surface Roughness in Finish Turning: Simulation Study

This paper presents the results of simulation analyses carried out to investigate the effect of adding controlled vibration of varying amplitudes and frequencies onto simulated workpiece profiles on surface roughness. The surface profiles were generated using the nose edge image of a real cutting tool insert at various stages of wear. The invariant moment sub-pixel edge detection method was used to extract the precise tool nose profile. The extracted nose profile was duplicated 20 times to generate the simulated workpiece profile. Vibration signals in the form of sine waves of amplitudes 0 to 50 % of the peak-to-valley height of the original workpiece profile and various frequencies were added to the simulated profile. Noise signals emanating from real machining were also added to the original profile to investigate their effect on roughness. The simulation study has shown that average roughness may increase continuously or fluctuate randomly depending on the magnitude of vibration added to the vibration-free workpiece profile. In the absence of vibration, the surface roughness of the workpiece decreases due to flattening effect of the tool nose during early stages of tool wear.

Optimization of cutting parameters of hybrid metal matrix composite AA6061/ZrB2 and ZrC during dry turning

The predominant aim of the research has been meant to evaluate cutting characteristic features of machining on AA6061/ZrB2-ZrC hybrid composite metal matrix with polycrystalline diamond tool. Though researchers understand, Taguchi would be used for dry turning operations to find the optimal cutting parameters. We have used the Taguchi L16 orthogonal array in the current investigation to evaluate the cutting characteristics. Through this work it’s analyzed that the optimal cutting as well as main cutting parameters actually affects the cutting performance. In order to understand the effectiveness of investigational optimization, confirmatory tests have been carried out hybrid composites fabrication composite has proved that it has better machining characterization. Hence, the fabricated composite can be recommended for applications especially hypersonic flight and rocket propulsion systems and because of the presence of hard ceramic material it is used commercially for the manufacture of cutting tools inserts.

Studying the Distribution of Temperature on Cutting Tool

The aim of this project is to study and compare the distribution of temperature on cutting tool by: 1. Varying the geometry of the cutting tool insert. 2. By changing the materials used in the tool insert. 3. And by changing the surrounding conditions such as cutting fluid and temperature. Three different materials were used for cutting tool inserts which were High- speed steel (HSS), Tungsten carbide (WC), and Cubic boron nitride (cBN). Triangular and square-shaped tool inserts were chosen for analysis and simulation was carried out at different cutting conditions. Thermal analysis was carried out by modelling the single point machining tool insert in Autodesk Fusion 360 and then studying its simulation analysis in ANSYS 2020 R2.

Performance analysis of micro textured cutting insert design parameters on machining of Al-MMC in turning process

Turning operation is one of the primary machining operations and enhanced machining performance is obtained by its process parameters. In turning process, heat is generated and it must be removed from the machining zone. Now a days, hydrocarbon oil based cutting fluid is used and it generates environmental issues as well as operator health issues. Recently, textured cutting tool inserts are attempted towards sustainable machining. In this work, turning process is carried out on aluminium-metal matrix composite (Al-MMC) with micro hole textured cutting tool inserts. Micro hole texturing involves various parameters such as hole diameter, hole depth and pitch between the holes. The main aim of this work is to analyze the effect of micro hole design parameters on machining performance. The input parameters include diameter of the micro hole, pitch between hole and hole and depth. Process outcomes include surface roughness, tool wear and power consumption. The experiments are performed based on L9 Taguchi orthogonal array. The result revealed that micro hole textured tools with solid lubricant embedded cutting inserts and its design parameters influence machining performance. Texture with solid lubricant could act as alternative to hydrocarbon oil based cutting fluid and also chip breaker.

Investigation of the tool wear, surface roughness, and chip formation in the machining of ZrO2-reinforced aluminum composites

The aim of this study is to reveal how ZrO2 (zirconia) contributes to the machinability of aluminum 1050. In the first stage of this study, composite materials were produced by the vortex method by adding different amounts of ZrO2 (5%, 10%, 20%, and 30%) into commercial aluminum of 99.5% purity. Then, microstructure images of composite materials were taken under the scanning electron microscope (SEM), and the hardness of these composite materials was measured. In the last stage, the machinability tests of the composite materials were performed on the lathe under dry machining conditions at 125, 175, and 225 m/min cutting speeds and 0.03–0.06 and 0.12 mm/rev feed rates, with 1.5 mm constant depth of cut. Uncoated cementite carbide cutting tool inserts were used in machining tests. SEM images of the cutting tool inserts were taken, and the roughness values of the machined surfaces were measured. Chip samples were taken and investigated. It was observed that all the cutting tools had a Built-Up Edge (BUE) formation. Surface roughness and BUE formation increased as the feed rates were increased and decreased with increasing cutting speed. The roughness values decreased slightly and then increased again depending on the ZrO2 ratio. As the feed rates increased, a transition from ribbon chip type to the helical and saw-toothed forms was observed. It was also observed that the chip formation changed depending on the amount of ZrO2 in the composite structure.

Advanced machining of miniature unmanned aircraft vehicle components using nanostructured cutting tools

The advanced machining of components used in miniature unmanned aircraft vehicles is the focus of this study. The finite element method (FEM) is used to predict forces and temperatures using cutting tool inserts with a thin nanostructured film of high integrity. Similarity models are used to validate the finite element results and to understand the influence of micromachining parameters on cutting temperatures generated when machining Al 380-0 alloy. The predicted results are compared to experimental forces and temperatures using a three-dimensional piezoelectric function dynamometer and a short-range infra-red wavelength thermal camera. Nanostructured thin layer coatings lower machining forces and temperatures, which are validated through FEM predictions and experimental observations. The experimental results suggest that increasing the cutting tool’s rake angle at higher depths of cut will reduce cutting temperatures, which are predicted using the similarity models for micromachining.

Minimum Quantity Lubrication through the micro-hole textured PCD and PCBN inserts in the machining of the Ti–6Al–4V alloy

A novel cutting tool development with the micro-hole textures on the flank and rake face of the cutting inserts helps in the reduction of tribological properties. The machining of Ti–6Al–4V alloy leads to some challenges during machining namely higher cutting temperature, and rapid tool wear. In this research, a comparison study has been performed with the new cutting tool inserts with surface modification such as Polycrystalline Cubic Boron Nitride (PCBN) and Polycrystalline Diamond (PCD) inserts for high-speed machining of Ti–6Al–4V alloy. The influence of the micro-hole textured insert on the machining of the Ti–6Al–4V alloy was investigated with the Minimum Quantity Lubrication (MQL) method. Compared to modified PCBN inserts, modified PCD inserts showed better results in all the performance characteristics.

Machine-learning for automatic prediction of flatness deviation considering the wear of the face mill teeth

The acceptance of the machined surfaces not only depends on roughness parameters but also in the flatness deviation (Δfl). Hence, before reaching the threshold of flatness deviation caused by the wear of the face mill, the tool inserts need to be changed to avoid the expected product rejection. As current CNC machines have the facility to track, in real-time, the main drive power, the present study utilizes this facility to predict the flatness deviation—with proper consideration to the amount of wear of cutting tool insert’s edge. The prediction of deviation from flatness is evaluated as a regression and a classification problem, while different machine-learning techniques like Multilayer Perceptrons, Radial Basis Functions Networks, Decision Trees and Random Forest ensembles have been examined. Finally, Random Forest ensembles combined with Synthetic Minority Over-sampling Technique (SMOTE) balancing technique showed the highest performance when the flatness levels are discretized taking into account industrial requirements. The SMOTE balancing technique resulted in a very useful strategy to avoid the strong limitations that small experiment datasets produce in the accuracy of machine-learning models.

The effect of transition-metal seeding powder on deposition and growth of diamond synthesized by hot filament chemical vapor deposition processes on cemented carbide substrates and its characterization

Hot Filament Chemical Vapor Deposition is a well-established method to synthesize diamond thin films on a non-diamond substrate. Here, we have deposited microcrystalline diamond on tungsten carbide cutting tool insert by using conventional Hot Filament Chemical Vapor Deposition technique. The substrates were ultrasonically seeded with Carbon, Diamond, Iridium, Molybdenum, Palladium, Platinum, Tantalum, Tungsten and Chromium natural powders and thereafter were deposited with the same deposition parameters to observe the effects of different seeding powders on the diamond coating. The coated tools were characterized by X-ray Diffraction and the quality of diamond crystals was assessed by using micro Raman spectroscopy. The surface morphology was studied by utilizing Scanning Electron Microscope. The discrete spherical diamond crystals were formed with carbon powder seeding while very dense along with uniform coatings were deposited on the diamond powder seeded substrate. Larger diamond crystals with good density were observed on the palladium seeded substrate. The micro Raman spectroscopy showed mixed results of sp3 and sp2 bonding. But the palladium seeding showed clear sp3 bonding due to the formation of crystals with bigger size. The Vickers microhardness value for the substrate with diamond seeding was found to be much higher than other coated tools.

Tool characteristics for better performance in machining ohns steel using coated tungsten carbide tool inserts

Turning Process is a significant machining process in which TiAlN covered tipped cutting tool inserts additions expel material from the outside of a pivoting round and hollow work piece. Machining of Oil Hardened Non Shrinking (OHNS) Steel is a challenge for production engineers in tool industry. In this examination paper, an investigation on turning OHNS Steel utilizing tungsten carbide instrument additions is made by shifting profundity of cut, feed rate and cutting rate each in turn and keeping other two consistent. 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.

Characterization of Micro-Crystalline Diamond Tools Synthesized by HFCVD Process with Different Seeding Powders

Synthesis of diamond films on carbide insert is a recent area of research in surface engineering. This research is carryout to know the effect of different seeding powders on diamond coating of WC tool by Hot Filament Chemical Vapor Deposition (HFCVD) method. Here, the formation of microcrystalline diamond (MCD) on SPUN tungsten carbide (WC-Co) cutting tool insert is carried out. Basically, before coating in HFCVD method, the substrate cobalt content should minimize by ultra-sonic etching. The uncoated tools are seeded ultrasonically by Diamond, Iridium, Platinum and Tungsten powder at the same coating condition to observe the growth of diamond crystals. X- ray diffraction gives clear results of diamond plane and adhesion of coating. The purity of diamond crystal after coating can be clear by observing the Raman shift in Raman spectroscopy (RS). The tool is seeded with diamond powder gives more nucleation density due to the presence of more sp3 bond as compared with sp2. Use of diamond and platinum powder as a seeding material gives fully developed crystal and uniform coating during diamond film deposition by HFCVD technique, rather in case of other powder coating the discrete crystals were formed.

The effect of cutting tool material on chatter vibrations and statistical optimization in turning operations

Machine tool vibrations consist of a self-stimulating mechanism during chip removal by machining operations. The system, which is a structural mode of the tool/workpiece, is initially stimulated by force. In turning operations, a wavy surface is formed on the workpiece because of both the previous revolution and structural vibrations. The maximum chip thickness may exponentially increase due to the phase shift between two consecutive waves, while the system oscillates at a chatter frequency very close to its structural mode. Variable growth in chip thickness increases vibrations, cutting forces and tool wear and causes a wavy surface. The purpose of the study is to compare different cutting tool inserts in terms of stable cutting depths. First, an experimental study was carried out and the stable cutting depths without chatter vibrations were determined in turning operations using various materials (AISI-1010, AISI-1050, Al-7075). Alumina inserts (Al2O3) were used in the study. Stable cutting depths were compared with the literature study that was performed using titanium carbide (TiC) inserts. A paired t test was used for the comparison. After the experimental study, a statistical/optimization study was performed to optimize stable cutting depths. It was observed that the chatter frequency was generally higher than the natural frequency of the cutting tool. Also, it was observed that the decrease in the number of revolutions, tool overhang lengths and yield strength of workpiece results in higher stable cutting depths. When the number of revolution is 125 rpm, the overhang length is 70 mm, and the yield strength is 124 MPa, the stable cutting depths maximize. In addition, stable cutting depths were higher when using Al2O3 cutting tool inserts and chatter vibrations were prevented. There was a significant difference between the two inserts (p < 0.05). It was found that the Al2O3 cutting tool inserts had better performances than TiC cutting inserts for the hard materials.

Probe geometry and surface roughness effects in microscale impact testing of WC-Co

ABSTRACT Depth-sensing repetitive microimpact tests have been performed on cemented carbide cutting tool inserts with spheroconical diamond probes with end radii of 8, 20 and 100 µm. Results were strongly dependent on the probe radius and applied load. At higher load, there was a transition to a faster damage rate marking the onset of more variability in rate and in the residual depth of the impact crater when using 8 and 20 µm probes. SEM images show the breakup of the WC skeleton at the periphery of the contact zone. Lower surface roughness slowed the initial damage rate at a higher load but did not significantly influence the final crater depth. The load-dependent fatigue mechanism displayed by the cemented carbide also has implications for the study and optimization of coatings when these are deposited.

Optimization of machining parameters during cryogenic turning of AISI D3 steel

This research paper depicts the process of used liquid nitrogen at the interface of TiN coated carbide cutting tool insert (rake face) and AISI D3 workpiece. Design of experiments (DoE) was planned according to Taguchi L9 (OA) orthogonal array. The experimental results during machining such as cutting force, machining time and temperature were optimized by Taguchi S/N ratio and analysed by ANOVA. The contribution of machining parameters of (i) speed, (ii) feed and (iii) depth of cut for each response were evaluated. Feed had the highest effect on the percentage of contribution of 57.21% and 52.21% for cutting force and machining time, respectively. Speed had the highest effect on the contribution as 79.57% for the temperature at the interface of insert and workpiece. The predicted values at the optimum level of machining parameters for cutting force, machining time and temperature were 44.49 N, 37.09 sec. and 24.99°C, respectively. Regression models were made. The R-Sq values were 96.59, 89.34 and 96.09% for cutting force, machining time and temperature, respectively. The ratio of an average thickness of generated chip and feed was considered as the chip compression ratio. It was observed that the generated chips during cryogenic turning were thin, discontinuous, long snarled and most of the material had side flow on either side.

Performance Evaluation of Cryogenic Treated and Untreated Carbide Inserts during Machining of AISI 304 Steel

The cutting tool in the machining process plays an important role as it acts on the working material. There are a few methodologies have been persued to improve tool life, for example traditional cooling, single layer coating, multilayer coating, heat treatment process, nitrogen cooling and latest being the cryogenic treatment which reported a significant improvement in cutting tool life, chip morphology, reduction in heat generation. Hence, the cryogenic treatment is emerged as the sustainable machining process. This paper presents machining of AISI 304 steel using both cryogenic treated (CT) and untreated (UT) cutting tool insert. The commercially available uncoated carbide insert has been cryogenically treated at -196°C for 24 hours soaking period. The machining test has been conducted under four different cutting speeds. The material characterization of cutting insert is studied by using scanning electron microscopy (SEM), hardness test, and microscopic image analysis has been carried out before and after cryogenic treatment. The cutting tool performance is assessed in terms of of wear, cutting temperature, chip morphology, surface roughness under the influence of cryogenic machining and the results are contrast with UT one. The exploratory findings reveals that the deep cryogenic treatment (DCT) with 24 hours soaking period, performed better wear resistance and improved surface roughness of the cutting tool. Also considerable reduction in the flank wear, crater wear, cutting temperature is obtained and found improved chip morphology.

Technical performance of nano-layered CNC cutting tool inserts – An extensive review

Quality of any machined products is directly influenced by the condition of cutting tools. Wear resistant coatings are found to be compelling in enhanced properties and performance of cutting tools. The main objective of this article is to emphasize recent advances in nano structural coatings of textures with 10 nm or less, combination of nano textures. These nano coated CNC inserts showed enhanced wear resistance and improved efficiency owing to the presence of hard materials such as Ti, TiN, TiCN, TiAlN, AlTiN, SiNZrN, AlCrN, etc. On the other hand, the influence of nano composite multi- layered hard coatings is more effective under severe environmental conditions. Thin film coating techniques has experienced great developments and it is currently conceivable to develop nano multi-layered and nanocomposite coatings with amazing properties. This review summarizes several characterization techniques which are adopted to study the tribological, morphological and mechanical properties of deposited nano coating on cutting tool inserts.

Estimation of Stress-Deformed State of the Cutting Insert of a Disk Mill Using Computer-Aided Engineering

The efficiency of the assembly tool is largely determined by the cutting tool insert installation scheme, as well as by the accuracy of manufacturing mating surfaces and loading conditions. When milling the normal types of destruction of the cutting blade are chipping and micro-dyeing. In this regard, in order to improve the reliability of a tool, it is desirable to provide the most uniform distribution of stresses at the initial time. In the article, the stressed-deformed condition of a cutting blade of a disk mill is considered taking into account the schemes of the cutting tool insert basing, the clamping force and the external cutting force. The stages of solving the problem of determining the stressed-deformed condition design of a disk mill are shown. The ratios of the force of clamping of the cutting tool insert and external force are determined. The joint effect on the stress state of the cutting tool insert of the clamping force and external force is analyzed.

Effect of vegetable oils as cutting fluid on wear of carbide cutting tool insert in a milling process

This research focusses on the effect of vegetable oils, i.e. crude palm oil (CPO) and coconut oil (CO), used as the cutting fluid on the wear of carbide cutting tool insert in a face milling process. The performances of the tool, in term of wear and the surface roughness of the workpiece, were investigated and compared to those resulting from a similar milling process but using conventional cutting fluid, which is a commercial soluble oil emulsion (SOE). The results show that at the spindle speed of 360 rpm and the feed rate of 80 mm/min, the tool wear was smaller in the case of CO than that in the case of CPO cutting fluid, which is 0.16 mm2 compared to 0.40 mm2, respectively. The tool worn area in these cases are still larger than that in the case of SOE, which is 0.09 mm2. However, at higher spindle speed of 490 rpm and feed rate of 80 mm/min, the smallest tool worn area occurred for the case of CO cutting fluid, which is 0.04 mm2, compared to 0.1 mm2 and 0.11 mm2 for the case of CPO and SOE cutting fluids, respectively. As for the workpiece, the achieved surface roughness, Ra, were relatively similar for all the evaluated cases.