Cutting Tool Technology Research Articles

COMPOSITE METAL ALLOY-BASED CUTTING TOOL FOR HÖRLLER INDUSTRIAL PAPER CUTTING

The Hörller industrial paper cutting requires tools of high precision and durability to meet the needs of the printing and packaging industry. This article covers the development of an innovative cutting tool based on a composite metal alloy, designed to address the specific challenges of this process. The main objective of this study is to design and manufacture a cutting tool that is able to meet the demands of industrial paper cutting type Hörller, providing high efficiency, quality and extended service life. The development process of the cutting tool involved the precise definition of the geometry, the careful selection of the composite alloy material, the application of heat treatment and specialized sharpening techniques. Detailed tests were conducted to evaluate the tool's performance under industrial conditions. The results demonstrate that the cutting tool based on the composite metal alloy provides a remarkable efficiency in the cutting of Hörller-type paper, significantly surpassing conventional alternatives. In addition, its durability has been proven in long periods of industrial operation, minimizing the need for maintenance. This study contributes to the advancement of industrial cutting tool technology, offering a robust and effective solution for Hörller-type paper cutting. The developed tool represents a milestone in the optimization of the cutting process, promoting greater productivity and quality in the printing and packaging industry.

Machining of Custom-450 Grade Stainless Steel Using TiAlSiN-Coated Tungsten Carbide Tool Inserts

Turning operations using single-point cutting tools have been one of the earliest and most used methods for cutting metal. It has been widely studied for cutting forces and workpiece surface roughness to affect turning operations. When cutting metal, the cutting tool needs to be tougher than the workpiece so it can resist high temperatures and wear while the operation is conducted. The mechanical qualities of martensitic stainless steel (MSS) grade Custom-450 can be significantly enhanced by heat treatment processes, which also provide it with an outstanding corrosion-resistance material. It has excellent resistance to rusting and pitting in a saltwater environment. Nuclear power reactors, screens for the pulp and paper sector, chemical processing, and power generation are just a few industries that require Custom-450 grade steel. To increase the workpiece’s machinability, dimensional precision, and appealing surface finish, the cutting tool industries have recently demonstrated a great interest in developing hard coatings and cutting tool technology. In the present study, Custom-450 grade stainless steel was used for machining (turning operation), using a tungsten carbide tool insert coated with TiAlSiN using the physical vapor deposition (PVD) method. The machining parameters such as the speed, feed, and depth of cut (DOC) were varied Surface roughness and various forces (cutting force, thrust force, and feed force) were evaluated by varying these three parameters. The depth of cut is the main factor affecting the surface roughness. More plastic deformation may lead to a rougher surface as a result. The tungsten carbide insert wear decreased with an increase in the cutting speed. An increase in feed considerably accelerates the tool wear of the inserts. As the depth of cut grows, the likelihood of tool wear also increases. The depth of cut, however, has a greater effect on tool wear than anything else. Therefore, the surface roughness in the sample is reduced as the cutting speed is increased.

A Comprehensive Review on the Conventional and Non-Conventional Machining and Tool-Wear Mechanisms of INCONEL®

Nickel-based superalloys, namely INCONEL® variants, have had an increase in applications throughout various industries like aeronautics, automotive and energy power plants. These superalloys can withstand high-temperature applications without suffering from creep, making them extremely appealing and suitable for manufactured goods such as jet engines or steam turbines. Nevertheless, INCONEL® alloys are considered difficult-to-cut materials, not only due to their superior material properties but also because of their poor thermal conductivity (k) and severe work hardening, which may lead to premature tool wear (TW) and poor final product finishing. In this regard, it is of paramount importance to optimise the machining parameters, to strengthen the process performance outcomes concerning the quality and cost of the product. The present review aims to systematically summarize and analyse the progress taken within the field of INCONEL® machining sensitively over the past five years, with some exceptions, and present the most recent solutions found in the industry, as well as the prospects from researchers. To accomplish this article, ScienceDirect, Springer, Taylor & Francis, Wiley and ASME have been used as sources of information as a result of great fidelity knowledge. Books from Woodhead Publishing Series, CRC Press and Academic Press have been also used. The main keywords used in searching information were: “Nickel-based superalloys”, “INCONEL® 718”, “INCONEL® 625” “INCONEL® Machining processes” and “Tool-wear mechanisms”. The combined use of these keywords was crucial to filter the huge information currently available about the evolution of INCONEL® machining technologies. As a main contribution to this work, three SWOT analyses are provided on information that is dispersed in several articles. It was found that significant progress in the traditional cutting tool technologies has been made, nonetheless, the machining of INCONEL® 718 and 625 is still considered a great challenge due to the intrinsic characteristics of those Ni-based-superalloys, whose machining promotes high-wear to the tools and coatings used.

Mobility and settlement dynamics of Large Cutting Tool makers in the subtropical forests of South China: A simulated ecological approach

New research in recent years has enriched our understanding of the spatio-temporal distribution of Large Cutting Tool (LCT) technology in Paleolithic China. Yet, few studies have focused on hominid social behaviors, and by analyzing LCTs from the Baise Basin in southern China, this case study aims to clarify some of these strategies for the region. Specifically, by employing two primary lines of evidence that consider both quantitative environmental variables and technological tool attributes, the results suggest that hominids preferred to adopt behavioral strategies associated with short-distance travelling and small-territory ranging. Furthermore, given the low density of stone artifacts and LCTs in all excavated sites, the somewhat homogenous landscape, and the even distribution of plant-dominated resources throughout the basin, site occupation and/or settlement was likely temporary in nature. Overall, the use of ecological simulations and analogous approaches in this study provides a series of new data for understanding lifeways of early humans in the humid subtropical forests of South China, and equally important, promote new research avenues for understanding the dynamics of the Chinese Paleolithic.

Future research directions in the machining of Inconel 718

Inconel 718 is the most popular nickel-based superalloy, extensively used in aerospace, automotive and energy industries owing to its extraordinary thermomechanical properties. It is also notoriously a difficult-to-cut material, due to its short tool life and low productivity in machining operations. Despite significant progress in cutting tool technologies, the machining of Inconel 718 is still considered a grand challenge. This paper provides a comprehensive review of recent advances in machining Inconel 718. The progress in cutting tools’ materials, coatings, geometries and surface texturing for machining Inconel 718 is reviewed. The investigation is focused on the most adopted tool materials for machining of Inconel 718, namely Cubic Boron Nitrides (CBNs), ceramics and coated carbides. The thermal conductivity of cutting tool materials has been identified as a major parameter of interest. Process control, based on sensor data for monitoring the machining of Inconel 718 alloy and detecting surface anomalies and tool wear are reviewed and discussed. This has been identified as the major step towards realising real-time control for machining safety critical Inconel 718 components. Recent advances in various processes, e.g. turning, milling and drilling for machining Inconel 718 are investigated and discussed. Recent studies related to machining additively manufactured Inconel 718 are also discussed and compared with the wrought alloy. Finally, the state of current research is established, and future research directions proposed.

Experiment analysis the effect of different parameters during slot cutting by using Taguchi technique identified tool wear behavior

In recent decade’s machine tools and cutting tool technology, (EDM) is utmost trending techniques for making factual shape on different material like HSLA, H11, H-13 etc. steels and is maximum endorsed techniques to be ensure for mold & die making. In Electric discharge machining process increases the mechanical and physical properties when used with powder suspension and with assertive composite of electrode materials. Result analysis through the effect of parameters and their level of practically examined least number of experiments trail by during slot cutting by using Taguchi technique identified tool wear. Now a day’s most prominent materials which are largely used in die making & mold casting industries like HSLA, H11 die steel. In the latent research M.R.R and T.W.R examined through the result analysis by the taugchi techniques changes in the level of the selected parameters. Selected parameters like electric current, pulses-on time, graphite and tungsten powders imposed in dielectric by changes the range of different levels with or with-out using magnetic fields. To find out the better result of analysis we followed the ANOVA techniques to optimize and the effects of the parameters at optimum level/range for the M.R.R and T.W.R of the cooper tool.

Performance study of dimple and channel textured tools during turning of Inconel-718

Alterations in cutting tool surfaces are being looked at as futuristic developments in cutting tool technology. Tool surface texturing by subtractive as well as an additive way can contribute to the tool performance and productivity improvement. The tool textures can be in the range of nano to micro-level. They help to reduce friction, manage the heat-induced during machining and facilitate chip removal. For textured surfaces, small cavities or dimples uniformly distributed over the sliding surface have been found to have the best tribological effect. In this study, two different micro-texture patterns i.e., micro-dimple and micro-channel were made on the rake-face close to the main cutting edge of the carbide tool insert. Ultra-short pulsed (nanosecond) fiber laser has been used for texturing. An array of texture patterns with 80 µm width/diameter and 70 µm depth has been engraved on the uncoated tungsten carbide tool. The textured inserts have been used for machining trials at 30 m/min to 100 m/min for Inconel 718 to compare the relative performance of the textures in terms of three components of cutting force and machined surface roughness. The experimental observations showed higher components of cutting force for channel textured tools in comparison to dimple textured tools. However, a better surface finish has been observed with channel textured tools. Cutting forces has been observed varying significantly with cutting speed in the case of dimple textured tools. Radial forces were observed higher in magnitude followed by tangential cutting force and feed force for both the textured tools. This study suggests having further studies considering the effect of different texture patterns on the cutting forces, surface roughness, and tool life while turning Inconel 718.

Surface finish generated in turning of medium carbon steel parts using conventional and adhesive bonded tools

Abstract Cutting tool technology is fully developed to the maximum extent. Still, an alternate cutting tool material is gaining popularity against conventional tool materials over the past few years. A bonded tool with Ana bond 220, as an adhesive is being searched for its feasibility. This paper reports some important characteristics of the surface roughness produced in the turning of a medium carbon Steel using adhesive bonded tools and conventional brazed tools. Experimentation is performed and surface roughnesses are measured. A statistical mathematical model of the process is obtained by using factorial experimentation, regression analysis and movement along the gradient. The coefficient of correlation R values for the surface roughness for all the models represented are in the range of 0.965–0.992, indicating the better correlation between the experimental and predicted values. A function approximation method is used to train the neural network with different optimization algorithms, transfer functions and topology. Overall neural network performed very well with coefficient of determination R2 as 0.977 and 0.978 respectively for the adhesive bonded tools and brazed tools. Finite element analysis is successfully used as an alternate tool to comprehensively represent the performance of adhesive bonded tools in the metal cutting operation. The surface roughness of the machined components produced by the adhesive bonded tools are significantly less than that with brazed tools and hence adhesive bonded tools is a better alternative with distinct advantages in the field of tool manufacturing.

Tribological behavior of textured tools in sustainable turning of nickel based super alloy

In this research study, textured tools were fabricated and used for machining under different cooling conditions. The most important uniqueness of the work lies in the use of textured tools for machining Inconel-718 under dry, Nitrogen cooling and nanofluids (hBN mixed with minimum quantity lubrication) conditions. In the turning experiments, two different level of cutting speed i.e., 75 and 125 m/min and a constant level for feed rate (0.1 mm/rev) and depth of cut (0.5 mm) were considered. The above three conditions were tested and compared with and without the use of textured tools. The tool wear, surface roughness, cutting temperature, micro-hardness of machined samples and chip morphology were investigated under these subjected conditions and at turning parameters. The results demonstrated that the nanofluids with textured tool provide the superior results in comparison with other cooling conditions. These results establish textured tools as a sustainable alternative to the existing cutting tool technology being used in the manufacturing industry.

Refining the Understanding of Large Cutting Tool Technology in the Baise Basin, South China

ABSTRACT Ever since the first discovery of handaxes in the 1970s in the Baise (Bose) Basin in South China, this region has been providing important data that have improved our understanding of Large Cutting Tool (LCT) technology in China. However, presently there are still some obvious shortfalls in our understanding of this very significant cultural paleolandscape. For instance, previous studies have only analyzed small or incomplete sub-samples of much larger collections, especially of the LCTs often from surface contexts, and in addition recent studies have also largely focused on the analysis of LCT morphological indices, versus adopting a more holistic approach that considers fundamental technological attributes. As a result, this study aims to provide a more detailed quantitative assessment of an expanded LCT and artifact sample, and furthermore, provide important insight into the spatial and temporal variability of Large Cutting Tool technology from a wider geographical and environmental perspective.

A review on cutting tool technology in machining of Ni-based superalloys

In this paper, a state-of-the-art review on cutting tool technology in machining of Ni-based superalloys is presented to better understand the current status and to identify future directions of research and development of cutting tool technologies. First, past review articles related to the machining of Ni-based superalloys are summarized. Then machinability of superalloys is introduced, together with the reported methods used in cutting tool design. The current researches on cutting tools in the machining of superalloys are presented in different categories in terms of tool materials, i.e., carbide, ceramics, and Polycrystalline cubic boron nitride (PCBN). Moreover, a set of research issues are identified and highlighted to improve the machining of superalloys. Finally, discussions on the future development are presented, in the areas of new materials/geometries, functional surfaces on the cutting tool, and data-driven comprehensive optimization.

Experimental Research and Optimization of Cutting Parameters for High Speed Machining

High Speed machining has captured popularity over last few years; Due to technological enhancements its implementation was successful. Because of progressive growth in machine tools and cutting too technology, HSM has proved itself an economic manufacturing process for manufacturing parts with high fidelity and surface quality. In recent times, with the progress of cutting tool technologies, HSM has also been used for machining alloy steels for preparing molds/dies employed in the manufacturing of a broad collection of automotive components, and also for plastic molding parts. This mechanization was effectively used with some advancement in machine tools, controllers and spindles. [1, 2]. The goal of this research is to develop mathematical models, in terms of the High-speed Milling operation input parameters. These models will assist engineers and technologists to achieve desirable machining conditions. This approach will assure the highest Depth of Cut, and assist in lowering machining time. Furthermore, it will reduce the numbers of experiments without any significant loss in the accuracy of the models developed.

Cutting tools characteristics and coating depositions for hard part turning of AISI 4340 martensitic steel: A review study

With the introduction of novel super cutting hard tool materials the innovative hard part turning process has cogently replaced by conventional grinding operations. Coatings have a deep-seated effect on cutting output characteristics. Coated tools can diminish considerably the coefficient of friction tends to minimisation of machining forces and surface machined roughness of the work even at more cutting paces. Evolution of the cutting practice has been convoyed by the continuous growth of cutting tool performance because of evolution of thin coatings that providing significant characteristics for every cutting setting. The layer on tool acts as imperative pillar in enhancing the wear resistance. Moreover, the cutting tool characteristics can be advanced during exploiting the coating layer Physical Vapour Deposition (PVD) or Chemical Vapour Deposition (CVD) of Titanium nitride (TiN), Titanium Carbonitride (TiCN), Titanium Aluminium Nitride (TiAlN), Aluminium Chromium Nitride (AlCrN) etc. This take stock summarizes the properties of PVD and CVD multilayer coating and further identification of research challenges from the perspective of cutting tool technology related with tribological phenomena. High strength low alloy steels (HSLA), for instance, AISI 4340 steel are extensively used in automotive, defence and aerospace scenario. In view of attaining better process efficiency, this report will map out the tool characteristics that can be practically fill the window for the researchers to accomplish further investigation on the machining performance of this alloy steel.

Pengembangan Produk Unggulan Daerah Berorientasi Ekspor Pada Industri Kerajinan Batu Alam Nusa Tenggara Timur

Regional superior products in NTT Province are currently the main pillars of the people's economy. Through the development program of superior products of export-oriented regions in the natural stone handicraft industry in UD Pesona Batu Alam, it is able to increase productivity, turnover and other assets. The support of Kupang State Polytechnic through the improvement of innovation-based mechanization on the types and kinds of production needed by the community through craftsmen in UD. Pesona Batu Alam is very necessary. Measured activities include the development of rock type designs through a variety of forms to attract tastes of domestic and foreign customers. The implementation methods that are carried out include the manufacture and application of cutting tool technology and portable stone grading screw systems to be part of the innovation targeted in this service program. The characteristics of the tool are designed in accordance with the conditions of natural stone and NTT Province's distinctive limestone products. The results of this service program are able to improve the quality of products, including the use of by-products in addition to being able to stimulate sales and marketing between islands and between neighboring countries.

Study of Heat Generation and Cutting Accuracy Depending on Spindle Rotation Speed Change in Ultra-Precision Cutting Using ECTS

At present, ultra-precision cutting technology has been studied in Korean research institutes, focusing on development of ultra-precision cutting tool technology and ultra-precision control engineering. However, the developed technologies are still far behind advanced countries. It focuses on metals including aluminum, copper and nickel, and nonmetals including plastics, silicone and germanium which require high precision while using a lathe. It is hard to implement high precision by grinding the aforementioned materials. To address the issue, the ultra-precision cutting technology has been developing by using ultra-precision machine tools very accurate and strong, and diamond tools highly abrasion-resistant. To address this issue, this study aims to conduct ultra-precision cutting by using ECTS (Error Compensation Tool Servo) to improve motion precision of elements and components, and compensate for motion errors in real time. An IR camera is used for analyzing cutting accuracy differences depending on the heat generated in diamond tools in cutting to examine the heat generated in cutting to study cutting accuracy depending on generated heat.

A life cycle approach to characterizing carbon efficiency of cutting tools

Cutting tools are extensively used in subtractive manufacturing systems for achieving the desired products. The advancement of cutting tool technology promotes the development of efficient and green machining. However, as one of the auxiliary consumptive materials, cutting tools have a crucial impact on the sustainability of machining systems. Thus, the development of sustainability urgently requires characterizing the impacts of cutting tools. This paper investigates the environmental impacts of cutting tools from the life cycle aspect based on the material and energy consumption during the material extraction, manufacturing, use, and recycling of cutting tools. Carbon emission is applied to measure the impacts of cutting tools on the sustainability of the machining system. Then a life cycle carbon efficiency approach based on the service life of the cutting tool is presented to characterize the life cycle carbon emission characteristics of cutting tools. A gear hobbing system with five kinds of hobs was introduced as a case study to characterize the life cycle carbon emissions and efficiency of hobs. It indicates that substrate and coating material type, manufacturing process, coating method, and regrinding times all influence the carbon emissions and efficiency of hobs to different extents. A high-speed dry-cutting hob exhibits excellent carbon efficiency in addition to carbon emissions.

Solutions for Sustainable Machining

The manufacturing industry contributes over 19% to the world's greenhouse gas emissions (U.S. Energy Information Administration, 2008, “Rep: Annual Energy Review 2008,” Report No. DOE/EIA-0384; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.) and 31% of the total energy consumed annually in the U.S. (Herzog, T., 2005, “World Greenhouse Gas Emissions in 2005,” World Resources Institute, Washington, DC 2; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.). There is therefore an increasing demand for sustainable solutions for the production technology industry. At the Technische Universitat (TU) Berlin, Germany, a collaborative research center (CRC) is focusing on new solutions for the sustainable machining of high performance alloys, with developments from machine tool frames to cutting tool technology being undertaken. An innovative machine tool concept with a modular frame, which allows a high level of flexibility, has been developed. Furthermore, add-on upgrading systems for older machine tools, which are particularly relevant for developing countries, have been developed. These systems allow the accuracy of outdated machine tools to be increased, thus making the machine tools comparable to modern systems. Finally the cutting process also requires solutions for dry machining, as the use of cooling lubricant is environmentally damaging and a significant cost contributor in machining processes. Two solutions are being developed at the TU Berlin: an internally cooled cutting tool and a heating concept for ceramic tools to allow dry machining of high temperature alloys, for example, for the aerospace industry.

Developments in cutting tool technology in improving machinability of Ti6Al4V alloy: A review

Ti6Al4V is the most widely used titanium alloy and is a demanding material in applications requiring high specific strength and corrosion resistance, that is, aerospace, automobile and biomedical industries. However, the poor machinability of this alloy, resulting from its low thermal conductivity, high hardness at elevated temperatures, high chemical reactivity with the cutting tool and low elastic modulus, restricts its usage. As a result, the tool life in machining of Ti6Al4V is substantially less than conventional materials such as steel and aluminium. This work reviews the various techniques employed in improving the machinability of Ti6Al4V alloy, from the perspective of cutting tool technology. The focus is onto the parameters affecting tool life in machining of Ti6Al4V alloy with some trending techniques and their feasibility, considering the economics to develop the best techno-economic method.

Research Progress in Technology of Diamond Cutting Tools

With the improvement of machining technology, diamond cutting tools are used more and more widely due to the excellent performance of diamond. This document briefly introduced the diamond cutting tool materials and the synthetic technologies, as well as the types of diamond cutting tools. Development situation of methods of machining diamond cutting tools and the grinding technology were also expounded. At the end of the dissertation, summery and future trends of diamond cutting tool technologies were outlined.

How old are the Bose (Baise) Basin (Guangxi, southern China) bifaces? The Australasian tektites question revisited

New research in recent years has enriched our understanding of the spatio-temporal distribution of Large Cutting Tool (LCT) technology in Paleolithic China. Yet, few studies have focused on hominid social behaviors, and by analyzing LCTs from the Baise Basin in southern China, this case study aims to clarify some of these strategies for the region. Specifically, by employing two primary lines of evidence that consider both quantitative environmental variables and technological tool attributes, the results suggest that hominids preferred to adopt behavioral strategies associated with short-distance travelling and small-territory ranging. Furthermore, given the low density of stone artifacts and LCTs in all excavated sites, the somewhat homogenous landscape, and the even distribution of plant-dominated resources throughout the basin, site occupation and/or settlement was likely temporary in nature. Overall, the use of ecological simulations and analogous approaches in this study provides a series of new data for understanding lifeways of early humans in the humid subtropical forests of South China, and equally important, promote new research avenues for understanding the dynamics of the Chinese Paleolithic.