Cutting Tool Temperature Research Articles

Effects of Spray Cooling Process Parameters on Machining Performance AISI 316 Steel: a Novel Experimental Technique

Machining performance of AISI 316 stainless steel turning under dry and spray impingement cooling environments was investigated. The input parameters such as depth of cut, feed rate, cutting speed, water pressure and air pressure were considered for the spray assisted turning with uncoated carbide inserts. All the experiments were carried out using Taguchi based L16 orthogonal array of the design of experiments. Cutting tool temperature, chip temperature, surface roughness and tool flank wear were the measured machining performance responses. The machining performance responses were simultaneously optimized using Taguchi based Weighted Principal Component Analysis approach. The optimal combination of the machining parameters under spray impingement cooling was found to be 0.2 mm depth of cut, 0.04 mm/rev of feed rate, 66 m/min of cutting speed, 3.5 bar of water pressure and 1.5 bar of air pressure. The optimized result was verified through confirmatory experiments and an improvement in the SN ratio of 18.1540 dB for Combined Quality Loss (CQL) was obtained. Machining under spray impingement cooling environment was most effective in turning AISI 316 steel in comparison with dry machining since reduction in chip temperatures were found out to be greater than 300%.

Thermal and tool wear characterization of graphene oxide coated through magnetorheological fluids on cemented carbide tool inserts

The proposed work is about the investigation of nano-textured tool insert with magnetorheological-based graphene coating process. The comparative study on nano-textured carbide insert with unpolished one for turning duplex stainless steel (S31803/2205) is made by conducting number of experiments with Box–Behnken design using response surface methodology. An array of sensor based on the conductive element of chromel and alumel core integrated through DC magnetron sputtering on the rake surface of the tool insert. The performance of the proposed sensor was evaluated from the obtained thermo-electromotive force on tool chip contact interference and the temperature measurements taken at the contours of multiple points with respect to the tool wear. Results obtained clarify that with the rise in cutting tool temperature leads to the rise in tool wear based on the adhesion and abrasion. It has been found that the graphene coated tool inserts provides high wearable resistances with flank wear of 0.298mm at 21st pass. The cutting tool temperature is found to spread uniformly with a value of 202°C for graphene coated inserts for cutting speed of 55m/min. Microstructural images taken proved that the formation of cementite and carbides with inter metallic compounds (IMCs) produced during the tool chip interface leads to the strengthening of tool tip in reducing the tool-wear. Also the occurrence of ultrafine grain boundaries on the tool tip occurs increasing the formation of covalent bonds in providing the robust resistance against tool wears.

High-speed edge trimming of carbon fiber-reinforced polymer composites using coated router tools

During trimming of edges of carbon fiber-reinforced polymer composite parts, issues such as resin degradation, delamination, and poor surface finish at the trimmed edges, and increased tool wear in cutting tools used is common. Therefore, it is essential to carry out investigations on edge trimming of carbon fiber-reinforced polymer to find the effect of cutting forces generated and the cutting tool temperature induced at different high speeds and feeds conditions. In this work, two different-coated router tools of titanium aluminum nitride-coated and diamond-like carbon-coated routers were used for investigating the effect of these coatings on cutting force and cutting tool temperature which affect the surface quality of trimmed carbon fiber-reinforced polymer. From the investigation, it was found that the diamond-like carbon-coated router tool has generated lower cutting forces, cutting tool temperatures, and, in turn, better surface finish even at high-speed conditions when compared to other tools. Due to the complex geometry of the router tool, online tool wear monitoring by acoustic emission technique was employed. Acoustic emission signals were taken as the measuring index of tool wear which shows good correlation with direct tool wear measurements. From the experiments, it was found that the tool performance of the diamond-like carbon-coated router is superior when compared to other tools. In addition, for edge trimming of carbon fiber-reinforced polymer composite parts, the diamond-like carbon router tool performed without much disturbance for a length of machining of around 5.9 m which is about 46% of increase in length of machining when compared to uncoated router tool.

Multi-criteria decision-making analysis of different non-traditional machining operations of Ti6Al4V

In the present study, different turning operations (conventional, ultrasonic-assisted and hot ultrasonic-assisted operations) of Ti6Al4V alloy were investigated by using a new multi-criteria decision-making method. In the first part of the study, conventional turning, UAT and HUAT operations were conducted, and they were compared to each other. The modal/chatter tests were performed through a hammer and recording chatter sound. Cutting velocity (10–40 m/min) and cutting tool overhang lengths (60 and 70 mm) were used as cutting parameters in the experiments. The full factorial experimental design was used. In the comparison of the turning operations, surface roughness, stable cutting depths and maximum cutting tool temperatures were considered. Also, variance analysis was carried out to optimize machining outputs. In addition, chip formation was observed. In the second part of the study, multi-criteria decision-making (MCDM) analysis was performed by using reference ideal method which has been recently presented in the literature to optimize machining outputs. Surface roughness, stable cutting depths and maximum cutting tool temperatures were selected as criteria to rank all the experiments. Based on MCDM results, higher cutting speeds, lower tool overhang lengths and ultrasonic-assisted turning are the appropriate levels of the cutting parameters. As a result, this study helps to understand new non-traditional machining methods in terms of MCDM perspective.

Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN.

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc., compared to wood. Medium density fiberboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests, three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analyzed using a multi-factorial analysis of variance (ANOVA).

Multi-objective optimization on the machining parameters for bio-inspired nanocoolant

The emphasis of this paper is to evaluate the thermophysical properties of crystalline nanocellulose (CNC)-based nanofluid and the optimized machining parameters (cutting speed, feed rate and depth of cut) for machining using CNC-based nanofluid. Cutting tool temperature and formed chip temperature during machining are determined with CNC-based coolant and metal working fluid. Minimum quantity lubrication technique is used to minimize the usage of the coolant. Nanocellulose coolant with a concentration of 0.5% shows better thermal conductivity and viscosity. Total heat produced at the cutting tool and the temperature generated at the chip during machining shows significant improvement using CNC-based nanofluid. Statistical analysis reveals that feed rate and depth of cut contribute around 27.48% and 22.66% toward cutting temperature. Meanwhile, none of the parameters significantly affects the heat transfer. The multi-objective optimization reveals that the optimum parameter for machining using CNC-based nanocoolant is: cutting speed = 120, feed rate = 0.05 and depth of cut = 1.78 which produces heat transfer of 379.44 J and cutting temperature of 104.41 °C.

Investigation of the stability on boring tool attached with double impact dampers using Taguchi based Grey analysis and cutting tool temperature investigation through FLUKE-Thermal imager

This article focuses on the investigation of machining characteristics of double impact dampers attached with boring tool and grey relational analysis (GRA) based multi-objective optimization for lower tool wear and better cutting force. Taguchi based orthogonal array method was exploited to formulate the experimental plan for the boring operation. Considering impact damper positions, speed and depth of cut as the input control factors, the output responses such as cutting force and tool wear were obtained from the L27 orthogonal array. ANOVA results exposed that damper position and speed had more effect on tool wear and cutting force respectively than depth of cut. Based on the obtained output response for cutting force and tool wear a comprehensive mathematical model was developed. The developed mathematical model for tool wear and cutting force predicted values similar to that of experimental results. The obtained result was corroborated clinched Fluke thermal image analyzer. Thermal imaging result showed that the optimized cutting conditions gives low tool temperature there by reduced tool wear can be obtained. Multi-objective criteria optimization was done through GRA technique and the recommended optimum parameters set provides better cutting force (Cf) of 342.47 N and less tool wear (Tw) of 0.22 mm.

Optimization of different non-traditional turning processes using soft computing methods

In this study, different non-traditional turning operations were investigated using various soft computing methods. In these operations, cutting speed, machining method, material type and tool overhang lengths were used as machining inputs. Surface roughness, stable cutting depths and maximum cutting tool temperatures were considered as machining outputs. In the first stage, artificial neural network, classification and regression tree (CART) and support vector machine models were developed to predict these outputs. In the second stage, an optimization study (regression analysis) was conducted. CART model produced better prediction results compared to the other methods. In CART models; 0.991, 0.998 and 0.959 values of correlation coefficients were calculated for the prediction of surface roughness, stable cutting depth and maximum cutting tool temperatures, respectively. In the optimization study, ultrasonic assisted/hot ultrasonic assisted turning methods, a tool overhang length of 60 mm and a cutting speed of 10 m/min provide optimum conditions. The proposed soft computing models will help to understand the effect of various parameters in non-traditional machining methods. These models will give a preliminary idea before the experiments. These models can be used as an alternative instead of 2D finite element machining simulations. Less analysis time is required compared to the finite element simulations.

Investigating effects of milling conditions on cutting temperatures through analytical and experimental methods

Cutting temperatures in milling operations have a significant impact on tool wear, size and shape tolerances and residual stresses of the machined part. Prediction and measurement of cutting temperatures in milling, on the other hand, have some challenges due to the rotary tools resulting in an intermittent process and transient thermal loadings. In this study, novel approaches are presented to model and measure the cutting tool temperature variations during milling. The model is used to predict effects of milling conditions on cutting temperatures particularly to determine a relationship between tool temperature and radial depth of cut. The model predictions are verified by measurements obtained from the developed measurement technique and the literature data.

FE simulation of machining of Ti-54M titanium alloy for industry relevant outcomes

Ti6Al4V is a well known alloy of Ti, although being a super alloy it shows poor machinability. Alternatively, another alloy of Ti (Ti-54M) has been introduced with improved machinability. It is observed from the literature that the new alloy Ti-54M exhibit superior machinability than Ti64. Therefore, the current study is focused on finite element modeling of the machining process on Ti-54M at three heat treated conditions, viz.: Solution Treated and Aged, Annealed and β Annealed. J–C constitutive material model has been employed to model the machining process. Cutting forces, feed forces, cutting tool temperature and chip morphologies were predicted by the model and validated from the experimental results. The error in the prediction was at 7% for cutting force, 9% for feed force and 10% for cutting tool temperature. The model has been further applied to study the effect of process parameters: heat treatment, depth of cut and cutting speed on the cutting forces and tool temperature. The model shows that the heat treatment does not show any effect on the material’s strength.

Numerical investigation of hot ultrasonic assisted turning of aviation alloys

Aviation alloys exhibit superior properties such as high-strength-to-weight ratio and corrosion resistance but these alloys possess poor machinability. To overcome this disadvantage, new machining methods (Ultrasonic assisted machining, hot machining, etc.) are developed. Hot ultrasonic assisted turning (HUAT) is a new hybrid machining method which changes the cutting system between tool and workpiece, therefore, reduced cutting forces and better surface finish for workpiece are obtained. In this study, 2D finite element (FE) analysis is carried out to investigate the effects of these machining methods on titanium and Hastelloy-X alloys in terms of cutting forces, cutting tool temperatures and effective stresses. DEFORM-2D software is used during analyses. In addition, an experimental study is conducted to verify numerical results. During verification, cutting tool temperature is taken into consideration. It is confirmed that HUAT technique reduces cutting forces and effective stress significantly but cutting temperature increases compared to conventional and ultrasonic assisted turning.

Cutting temperature and tool flank wear during turning aluminium matrix composite in air-water spray environment - a Taguchi approach

In this paper influence of machining parameters on cutting tool temperature (Tc) and tool flank wear (Fw) has been investigated while turning silicon carbide particulate reinforced Al 7075 matrix composite in air-water spray environment. Turning was conducted following Taguchi L16 orthogonal array, and the responses were optimized individually. 40 m/min of cutting speed (V), 0.05 mm/rev of feed (f) and 0.2 mm of depth of cut (d) was the optimal combination of process parameters for both Tc and Fw. Quadratic response surface models were developed and significance of process parameters on the responses was verified through Analysis of Variance (ANOVA).

Optimization of Machining Parameters in Turning of Al6063A-T6 using Taguchi-Grey Analysis

Aluminum alloys are widely used in the transportation, construction, marine, and aerospace. It possesses good corrosion resistance, wear resistance, high strength to weight ratio good formability. In present work an investigation of machining parameters speed, feed and depth cut which effect the surface rough of the workpiece and cutting tool tip temperature. Experiments are carried out with varying speed, feed and depth of cut on Al6063A-T6 on CNC turning machine using carbide tools. Taguchi-Grey analysis is carried out on L9 orthogonal array to find the optimum the speed, feed and depth of cut in order to have minimum surface roughness and low cutting tool temperature. From the results of analysis, it is found that optimum speed (N3) =1400rpm, feed (F1) =0.1mm/min and depth of cut (D3) = 0.75mm for which minimum surface roughness (Ra) is 0.855 microns and cutting tool temperature (T) =4570C in machining of Al6063A-T6 on CNC turning machine.

Multi-Objective Optimization during Hard Turning of AISI D2 Steel Using Grey Relational Analysis

This research focuses on the experimental work performed on AISI D2 steel having a hardness of 55 HRC. Hard turning experiments were conducted based on Taguchi's L27 orthogonal array by considering various machining parameters, tool geometry, cutting tool material and cutting conditions. Altogether eight process variables are used and three different levels are considered for all the variables involved in the experimentation. In general, hard turning process is highly complex and its complexity further increases as more number of operating variables are taken into account. In such a complex situation selecting the optimum cutting conditions for an favorable response in terms of surface finish, tool life, cutting tool temperature and metal removal rate is very difficult. Therefore an attempt is being made to determine the optimum set of process variables using an approach which combines orthogonal array design of experiments and grey relational analysis. Optimal values of all the eight machining variables were determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics.

Effect Of Machining Parameters On Cutting Tool Temperature And Tool Life While Turning EN24 And Hchcr Grade Alloy Steel

Converting raw materials in to the finished product is the primary objective of machining, in order to obtain desired quality in terms of surface texture and dimension. While machining alloy steels of grade EN24 & High Carbon High Chromium (HCHCr), the cutting tools are subjected to higher wear due to the presence of alloying elements such as chromium, vanadium and Molybdenum which leads to increase of cutting tool temperature and hence reduction in tool life. The tool life and cutting tool temperature study were carried out at varied cutting speeds, feeds and constant depth of cut. The experiments carried out following ISO3685 standards. The experimental results revealed that the tool life found higher during continuous turning of EN24 and HCHCr alloy steels with M15 grade multilayer coated carbide insert when compared to that of M20 grade multilayer coated carbide insert by around 35%.

Analysis of multipoint cutting tool temperature using FEM and CFD

Nimonic C-263 is a British nickel–chromium–cobalt–molybdenum alloy specially meant to be used in high-temperature and high-strength applications. Consequently, it produces high thermo-mechanical loads on the machining tool when machined. As a result, excessive heat is generated during dry drilling, between Nimonic C-263 and tungsten carbide tool coated with Alcorna, which in turn reduces the durability of the tool. In order to determine the temperature distribution of the tool, the coupling of finite element machining simulations along with computational fluid dynamics simulations is performed. The temperature distribution of the tool under dry condition is simulated via the DEFORM 3D software and the Altair AcuSolve software. Further investigation under cooling condition is performed using Altair AcuSolve software. The mass flow rate of the coolants is kept constant when the temperature distribution is obtained during the CFD analysis under cooling condition. Silver nano coolant has high heat reduction compared to other coolants and is found to generate 34% less heat than dry condition.

Ebaketa-erramintaren tenperaturak neurtzeko tornuko ebaketa eten bidezko fresaketaren simulazioa

Lan honetan zehar fresaketa bidezko simulazioa lantzen da tornuko ebaketa etenaren bitartez. Finkatutako helburu nagusia erremintaren jaulkitze-aurpegian lortuko diren tenperaturak ezagutzea izango da ebaketa prozesuan. Helburu hori lortzeko, torneaketa prozesutik fresaketa prozesura estrapolazio bat egingo da, luzeran artekatutako pieza torneatzen bada posible izango dena, torneaketa fresaketa izango balitz bezala simulatuz, fresaketa ebaketa etena denez. Proba-baldintzetan tenperatura-neurketa horiek gauzatzeko K motako termoparea erabiliko da, zein jaulkitze aurpegiarekiko 0,5 mm-ko distantziara kokaturik egongo den. Bero-transmisiozko modelo teoriko batean oinarrituz kalkulatuko dugu kontaktuko batez besteko tenperatura. Ebaketa-baldintza ezberdinetarako proba ezberdinak garatu dira eta sakontasunez deskriba- tuko ditugu. Horretaz gain, ebaketa jarraituan eta etenean lortuko diren tenperatura-diferentziak aztertuko dira, alde batetik, ebaketa-denbora berbera erabiliz eta, bestetik, ebaketa eraginkorraren luzera berbera erabiliz.

Experimental investigation of machining characteristics and chatter stability for Hastelloy-X with ultrasonic and hot turning

Ultrasonic-assisted machining is a machining operation based on the intermittent cutting of material which is obtained through vibrations generated by an ultrasonic system. This method utilizes low-amplitude vibrations with high frequency to prevent continuous contact between a cutting tool and a workpiece. Hot machining is another method for machining materials which are difficult to cut. The basic principle of this method is that the surface of the workpiece is heated to a specific temperature below the recrystallization temperature of the material. This heating operation can be applied before or during the machining process. Both of these operations improve machining operations in terms of workpiece-cutting tool characteristics. In this study, a novel hybrid machining method called hot ultrasonic-assisted turning (HUAT) is proposed for the machinability of Hastelloy-X material. This new technique combines ultrasonic-assisted turning (UAT) and hot turning methods to take advantage of both machining methods in terms of machining characteristics, such as surface roughness, stable cutting depths, and cutting tool temperature. In order to observe the effect of the HUAT method, Hastelloy-X alloy was selected as the workpiece. Experiments on conventional turning (CT), UAT, and HUAT operations were carried out for Hastelloy-X alloy, changing the cutting speed and cutting tool overhang lengths. Chip morphology was also observed. In addition, modal and sound tests were performed to investigate the modal and stability characteristics of the machining. The analysis of variance (ANOVA) method was performed to find the effect of the cutting speed, tool overhang length, and machining techniques (CT, UAT, HUAT) on surface roughness, stable cutting depths, and cutting tool temperature. The results show both ultrasonic vibration and heat improve the machining of Hastelloy-X. A decrease in surface roughness and an increase in stable cutting depths were observed, and higher cutting tool temperatures were obtained in UAT and HUAT compared to CT. According to the ANOVA results, tool overhang length, cutting speed, and machining techniques were effective parameters for surface roughness and stable cutting depths at a 1% significance level (p ≤ 0.01). In addition, cutting speed and machining techniques have an influence on cutting tool temperature at a 1% significance level (p ≤ 0.01). During chip analysis, serrated chips were observed in UAT and HUAT.

Optimisation of turning AISI 1040 steel with extreme pressure additive in vegetable oil based cutting fluids

This paper aims to obtain the optimal combination of machining parameters for multiple performance characteristics in the turning operation by implementing desirability function analysis. Experiments were conducted using machining parameters like different proportions (5%, 10%, and 15%) of extreme pressure additive in three different vegetable oil based cutting fluids (sesame, canola, and coconut oils), cutting speed and feed rate for evaluating the cutting force, cutting tool temperature, tool flank wear, and surface roughness. An orthogonal array (L27) was generated using the Taguchi design to carry out the experiments on AISI 1040 steel. Composite desirability was analysed for identifying the optimal levels of machining parameters. Experimental results revealed that cutting fluid had the most significant effect on cutting force, cutting tool temperature, tool flank wear, and surface roughness. Confirmation test was carried out to validate the results. Experimental results have shown that machining performance can be improved through desirability function analysis.

Influence of tool material and tool wear on tool temperature in hard turning reconstructed via inverse problem solution

In this work the cutting tool temperature distribution that develops during turning of hardened cold-work tool steel is modeled on the basis of experimental data. The data obtained from a series of thermocouples, placed on a PCBN insert, into an anvil, and into a toolholder, were used as the input for the model. An inverse problem was solved, where the heat fluxes were computed. The temperature distribution was modeled for the case of new tools, as well as for the case of its development in the course of a tool wear. The reconstructed temperature distributions were in good agreement with the measured data. The heat flux through rake face was found to be reducing with the decrease of thermal conductivity of the tool material.