Cutting Tool Research Articles

Vibration-Limited Composite Cutting Tool with Damping Elements

Vibration-Limited Composite Cutting Tool with Damping Elements

Study the Surface and Chip Formation of Wood Materials by Milling Method

This paper discusses the experimental study and the mechanism of chip formation, sliding and cutting in processing wood milling surface. The main objective is to determine chip thickness upon the coefficient k and tool tip radius ρ. Technically, when analysing we use FCCCD's second-order response surfaces method and analysis of variance (ANOVA) for determining the coefficient k upon the factors of milling cutter diameter D, the feeding per tooth Sz and tool tip radius ρ. According to the obtained experimental results, we determined the value domain of the machine's working factors so that the cutter tool tip can slide or cut the chip on the milled surface of tropical wood materials. From the coefficient k, we can determine the slide length Lsl which gives reason for the abrasion phenomenon of the front or rear sides of the cutter. The results allow us to choose the geometrical parameters ​​for milling cutter, apart from the working parameters for processing the surface of wood materials with the highest quality as possible.

Gaussian process regression model incorporated with tool wear mechanism

Cutting tool condition directly affects machining quality and efficiency. In order to avoid severely worn tools used during machining process and fully release the remaining useful life in the meanwhile, a reliable evaluation method of remaining useful life of cutting tools is quite necessary. Due to the variation of cutting conditions, it is a challenge to predict remaining useful life of cutting tools by a unified model. In order to address this issue, this paper proposes a method for predicting the remaining useful life of cutting tools in variable cutting conditions based on Gaussian process regression model incorporated with tool wear mechanism, where the predicted value at adjacent moments is constrained to a linear relationship by the covariance matrix of Gaussian model based on the assumption of progressive tool wear process, so the wear process under continuous changing conditions can be modelled. In addition to that, the input feature space and the output of the model are also enhanced by considering the tool wear mechanism for improving prediction accuracy. Machining experiments are performed to verify the proposed method, and the results show that the proposed could improve the prediction of tool remaining useful life significantly.

Elliptical torus cutter tool path generation based on minimum distance computation

In mould manufacture the elliptical torus cutters are used for their high cutting velocity, but the special geometry also brings issues in tool path generating and machining quality controlling. In this paper a guide curve tool path generating method for elliptical torus cutters is presented with the cutter location points computed by a minimum distance algorithm and the path spacing determined by an adaptive method. In the minimum distance algorithm, the calculation is resolved into an iterative process from point to freeform surface and an algebraic calculation process from point to elliptical torus surface considering the geometry of the cutter, which reduces the iterative process and improves the computing speed. In the adaptive path spacing method, the contacting geometry between the elliptical cutter and the workpiece surface is analysed and the relations among the scallop height, the tool tilt angle and the path spacing are deduced, based on which the guide curves are adjusted in advance to control the scallop height. Calculating examples and experiments are carried out, showing that the consuming time of cutter location (CL) points computation algorithm is reduced by 30% comparing to earlier method, and the adaptive path spacing method performs better than constant method in both scallop height controlling and tool path shortening. The results indicate that the presented tool path generating method can help to reduce both the machining and machine waiting time as well as ensuring the machining quality.

Statistical Analysis of the Effect of the Cutting Tool Coating Type on Sustainable Machining Parameters

Statistical Analysis of the Effect of the Cutting Tool Coating Type on Sustainable Machining Parameters

Effect of Boron and Vanadium Addition on Friction-Wear Properties of the Coating AlCrN for Special Applications.

Cutting tools have long been coated with an AlCrN hard coating system that has good mechanical and tribological qualities. Boron (B) and vanadium (V) additions to AlCrN coatings were studied for their mechanical and tribological properties. Cathodic multi-arc evaporation was used to successfully manufacture the AlCrBN and AlCrVN coatings. These multicomponent coatings were applied to the untreated and plasma-nitrided surfaces of HS6-5-2 and H13 steels, respectively. Nanoindentation and Vickers micro-hardness tests were used to assess the mechanical properties of the materials. Ball-on-flat wear tests with WC-Co balls as counterparts were used to assess the friction-wear capabilities. Nanoindentation tests demonstrated that AlCrBN coating has a higher hardness (HIT 40.9 GPa) than AlCrVN coating (39.3 GPa). Steels’ wear resistance was significantly increased by a hybrid treatment that included plasma nitriding and hard coatings. The wear volume was 3% better for the AlCrBN coating than for the AlCrVN coating on H13 nitrided steel, decreasing by 89% compared to the untreated material. For HS6-5-2 steel, the wear volume was almost the same for both coatings but decreased by 77% compared to the untreated material. Boron addition significantly improved the mechanical, tribological, and adhesive capabilities of the AlCrN coating.

Design and analysis on textured cutting tool

Cutting tool plays a major role in manufacturing process to reduce cost and machining time. Various number of researches had been conducted to optimize machining process and to find a way to extend the life of the cutting tool. To improve the process quality, the surface texturing is also performed on the cutting tool. In this paper, the machinability of textured tungsten carbide cutting tool for turning aluminum alloy is proposed. The texture pattern used in parallel stripes and vertical stripes on the flank of the cutting tool. The simulations of the texture pattern were engraved on the tool using Abaqus/CAE 6.14 software chip formation simulation had been done. Boundary conditions for the work is defined as displacement and rotation and the velocity is defined as 0.2 m/s. The meshing of the part and work is done in square mesh pattern and the discretization rate is 0.0005. From the analysis, the chip flow direction and the shear zone are discussed in detail. Subsequently, the energy developed on machine the material has been evaluated with the results of cutting force. The maximum cutting force developed in the plain cutting tool is 1.468 N. however, for the textured cutting tool has 1.207 N for horizontal texture tool and 3.249 N vertical textured cutting tool. It indicates that the horizontal has a built – up edge nature and supports to shear the material conveniently than the other two conditions. In addition, the stress induced during the machining process is also compared for interpretation. Thus, the inference is made to justify that the tool life is increased when surface texturing is done compared to the tool life for non-textured tool.

Analysing the life index of diamond cutting tools for marble building stones based on laboratory and field investigations

Cutting tool wear constitutes one of the principal parameters in the processing cost of building stone. The life index of the cutting tool is obtained by evaluating the wear of diamond segments in the processing plants and examining the main parameters thereof. The purpose of this study is to determine the life index of the diamond cutting tool by considering the physico-mechanical properties of marble stones and the operational parameter of cutting speed. To this end, a dataset was provided by collecting the data from eight building stone processing plants in the provinces of Tehran, Isfahan, and Yazd of Iran. In this regard, the number of square metres of building stone that every diamond cutting tool can cut during its lifetime is defined as the cutting tool life index (TLI). After collecting the required data, SPSS software was employed for statistical analysis. The results revealed that the Brazilian tensile strength is the main parameter that affects the cutting tool life index. Linear and non-linear regression analyses were then considered for the development of predictive models for the TLI based on the Brazilian tensile strength. The performance of the developed models was subsequently examined by using three different criteria: the coefficient of determination, the variance accounted for, and the root-mean-square error. The results of this study show that the non-linear predictive model of the TLI presents a very good performance, and thus, the diamond cutting tool life index can be obtained for marble stones by considering the model developed herein.

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials. The tool material characteristics under the external loads’ influence and the surface layer adaptation to the heat–power exposure conditions were shown by the temperature field study using a semiartificial microthermocouple method (the level of fields is reduced by 20%–25% for 80% HSS + 20% TiCN), frictional interaction high-temperature tribometry (the coefficient of friction did not exceed 0.45 for 80% HSS + 20% TiCN at +20 and 600 °C), laboratory performance tests, and spectrometry of the surface layer secondary structures. Spectral analysis shows the highest spectrum intensity of TiC2 after 5 min of running in. After 20 min of milling (V = 82 m/min, f = 0.15 mm/tooth), dicarbide decomposes and transits to thermally stable secondary phase films of good lubricity such as TiO (maximum) and TiN (partially). There was an increase in tool life of up to 2 times (>35 min for 80% HSS + 20% TiCN), and a decrease in the roughness of up to 2.9 times (Ra less than 4.5 µm after 25 min of milling).

Development of Optimal Design and Circular Broach Modular Design of Disc Cutters with the Development of a Parametric Model

Cutting tool is one of the most important instruments in production. It is used for machining of different components on machine tools. A material is cut into a chip to incur the desired work piece surface currently used in engineering various cutting tools. The directions of development of structures of metal cutting tools are: higher precision of dimensional and geometrical parameters, the use of new tool materials, cost, and quick. The cutting tools are not only affected by the design of machine, technology of manufacturing of products, but also impact the constructive forms of machine parts. The emergence of mechanical spine, thanks to the pull method. Spine broach can provide high-performance processing spine bore with the required accuracy. The development of heavy machine tools required the creation of new designs of large instruments. The use of mechanical automatic lines also required design tools with high dimensional stability capable of handling the items within the specified tolerance for a certain time. Instruments were developed in the process of renewing the cutting edge of the cutting tools with automatic adjustment; setting up tools on the size of the machine is a device for automatic replacement of worn tool in the process line of the Computer-Aided Manufacturing CAM of the cutting tool special requirements. Equipment must operate with high level efficiency, so to reduce the loss of time resetting of the need to minimal. A cutting tool requires knowledge of the theoretical foundations of design and calculation tools using CAD.

Modification of the Surface of a Reconditioned Cutting Tool via Laser Ablation

The article discusses the possibility of using pulsed laser ablation of nanosecond duration to modify the surface of a cutting tool after regrinding and restoration. Experimental studies of the resistance characteristics of cutting tools with modified surfaces via laser ablation in air and in liquid have been carried out. It was found that after modifying the surface of cutting plates via laser ablation in air, the wear on the trailing surface of the cutting tool at a processing speed of V = 50 m/min is 8 times less than that of the untreated one, the build-up is 20 times less. The wear of the trailing surface of the plates at V = 70 m/min is 2 times less than that of the untreated sample. The resistance studies show surface modification of the cutting tool increases the tool life of the remanufactured tool, overall tool life and savings in tool costs.

Estimation and Optimization of Tool Wear in Conventional Turning of 709M40 Alloy Steel Using Support Vector Machine (SVM) with Bayesian Optimization.

Cutting tool wear reduces the quality of the product in production processes. The optimization of both the machining parameters and tool life reliability is an increasing research trend to save manufacturing resources. In the present work, we introduced a computational approach in estimating the tool wear in the turning process using artificial intelligence. Support vector machines (SVM) for regression with Bayesian optimization is used to determine the tool wear based on various machining parameters. A coated insert carbide tool 2025 was utilized in turning tests of 709M40 alloy steel. Experimental data were collected for three machining parameters like feed rate, depth of cut, and cutting speed, while the parameter of tool wear was calculated with a scanning electron microscope (SEM). The SVM model was trained on 162 experimental data points and the trained model was then used to estimate the experimental testing data points to determine the model performance. The proposed SVM model with Bayesian optimization achieved a superior accuracy in estimation of the tool wear with a mean absolute percentage error (MAPE) of 6.13% and root mean square error (RMSE) of 2.29%. The results suggest the feasibility of adopting artificial intelligence methods in estimating the machining parameters to reduce the time and costs of manufacturing processes and contribute toward greater sustainability.

A Novel Fluid–Structure Interaction (FSI) Modeling Approach to Predict the Temperature Distribution in Single-Point Cutting Tool for Condition Monitoring During Turning Process

A Novel Fluid–Structure Interaction (FSI) Modeling Approach to Predict the Temperature Distribution in Single-Point Cutting Tool for Condition Monitoring During Turning Process

Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel

Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools.

Utility of Taguchi Grey Relation Analysis for Influencing the System Input Parameters and Impacts of Tool Geometry and Wear Response of the Cutting Tool on Machinability and Environmental Impact of Machining for Automobile Industries

Amid the delivering of an item, any material or abundance vitality created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a noteworthy ecological worry for creators. The shape and condition of waste streams created and their transportation components contrast with the strategy utilized and also shift among the technique. The effect in view of each waste stream differs as well. This examination reports a machining strategy includes the procedure of material to give a completed or a semicompleted item. This is frequently done to abuse tools, frills, machines and distinctive data sources that are appropriate to the strategy. The procedures for this work include machining of material abuse devices to give parts and items. The yield of the technique incorporates the item and thusly the waste streams. The waste streams convey with the material inside the kind of chips, energy usage, worn cutting tools and operating time. Grey relational analysis and ANOVA was acclimated with the chief essential cutting speed, feed rate, depth of cut and tool nose radius conditions that influence the minimum response. The cooperative effects of the informational factors on the normal reactions are researched. The normal and estimated esteems are genuinely close. The given model may be acclimated to pick the measure of machining process parameters.

Experimental Investigation of Cutting Tool In VMM-A-200 CNC Milling Machine

The project aims at effect of cutting forces on the drill & end mill cutter tools in modern manufacturing. For High-speed machining operation, accuracy of tool tip places a vital role in mass manufacturing. In order to get high precision, high-efficiency automated production the tool life should be longer enough to withstand various stresses acting on it. The main aim is to develop the combination of optimum cutting parameters by using taguchi method. In this project design of experiment has been employed with L9 (3^3) Orthogonal Array for three parameters namely Speed, Feed and Depth of cut. For each of these parameters three different levels have been identified and used to perform the cutting parameters for minimizing the stresses acting on various tool in SINEWAVE© VMM-A-200 CNC Milling Machine. The material selected for machining was Aluminium plate with drill & end drill cutter tools. Cutting forces are experimentally determined at a tip of cutting tools during machining by milling tool dynamometer. From the obtained cutting forces are applied on tip of cutting tools and results are evaluated using ANSYS software such as various stresses, strain and total deformation are found. Cutting Tools are modelled in CREO software and the model is then imported in ANSYS software for analysis. Also, from stress analysis of milling tool it is evident thrust force play a vital role in machining, whenever the stress is minimum then the tool life become maximum.

Application of hybrid Taguchi-Grey relational analysis (HTGRA) multi-optimization technique to minimize surface roughness and tool wear in turning AISI4340 steel

In this paper, an attempt is made to optimize the turning process by minimizing Surface Roughness and Tool Wear. The independent l factors used are Environmental Condition, Feed Rate, Depth of Cut, Nose Radius and Tool Types. The dependant factors are Surface Roughness and Tool Wear. Experimentations are conducted on CNC Spinner Lathe machine. AISI 4340 steel is selected as workpiece material. Three different types of Cutting tool are considered for the study. Grey Relational Analysis and Taguchi Philosophy together are used to optimize the process. As per the Taguchi method L27, Orthogonal Array (OA) is finalized for the experimentation. For the computation of the response table and ANOVA table, the Taguchi based data Analysis is used. The Variance Analysis (ANOVA) and S/N ratio (SRN) are employed to find the contribution and ranking of contribution parameters to optimize multiple output parameters.

Reliability of the Cutting Alignment Scoring Tool (CAST) to Assess Trunk and Limb Alignment During a 45-Degree Side-Step Cut.

BackgroundThree-dimensional (3D) motion analysis is considered the gold standard for evaluating human movement. However, its clinical utility is limited due to cost, operating expertise, and lengthy data processing time. Numerous qualitative scoring systems have been introduced to assess trunk and lower extremity biomechanics during functional tasks. However, the reliability of qualitative scoring systems to evaluate cutting movements is understudied. Purpose/Hypotheses: To assess the inter-rater and intra-rater reliability of the Cutting Alignment Scoring Tool (CAST) among sports medicine providers and to evaluate rater agreement of each component of the CAST. The hypotheses were: 1) there would be good–to-excellent inter-rater and intra-rater reliability among sports medicine providers, 2) there would be good to almost perfect agreement for cut width and trunk lean variables and moderate to good agreement for valgus variables of the CAST.Study DesignRepeated MeasuresMethodsTen videos of a 45-degree side-step cut performed by adolescent athletes were independently rated on two occasions by six raters (2 medical doctors, 2 physical therapists, and 2 athletic trainers). The variables assessed include trunk lean to the opposite direction of the cut, increased cut width, knee valgus at initial load acceptance (static), and knee valgus throughout the task (dynamic). Variables were scored as either present, which were given a score of “1”, or not present, which were given a score of “0”. Video sequence was randomized in each rating session, and a two-week wash out period was given.ResultsThe cumulative inter-rater and intra-rater reliabilities were good (ICC: 0.808 and ICC: 0.753). Almost perfect kappa coefficients were recorded for cut width (k=0.949). Moderate kappa coefficients were found for trunk lean (k= 0.632) and fair kappa coefficients were noted for dynamic and static valgus (k=0.462 and k= 0.533 respectively).ConclusionThese findings suggest that the CAST is a reliable tool to evaluate trunk and LE alignment during a cutting task by sports medicine providers.Level of EvidenceLevel 2 Diagnosis

A vision-based fusion method for defect detection of milling cutter spiral cutting edge

Cutting tool is one of the most important parts of machine tool which greatly influences the machining quality. Defect detection of cutting tool spiral cutting edge is usually done by quality control workers after manufactured, which costs time and the quality cannot be guaranteed. In order to detect defects on the spiral cutting edge automatically and reliably within limited cycle time, this paper proposes a vision-based fusion method. This method first uses improved Yolov3-tiny to extract the target cutting edge region, and then traditional image processing method is used to detect and evaluate defects. Compared with only using deep learning, the detection accuracy and evaluation precision of defects are improved. Compared with traditional image processing method, the robustness of illumination is improved. In the case study, the detection result shows that the proposed method can effectively detect and evaluate small defects on the spiral cutting edges illumination insensitively with high detection accuracy.

Software for the Problem of Constructing Cutting Tool Paths in CAD/CAM Systems for Technological Preparation of Cutting Processes

Most of the research on tool paths for cutting machines focuses on determining the path for contour cutting. State-of-the-art, resource-efficient sheet metal cutting technologies allow one to match the contours of the cut parts, thus reducing material waste and minimizing the cut length. However, the alignment of the boundaries of the cut contours is the source of a number of constraints formalized in terms of plane graphs: (1) ordered enclosing, (2) nonintersecting cutting path. The article considers the main data structures and algorithms used in the CAD/CAM system developed for technological preparation of cutting processes, which allows cutting plans with combined contours, as well as software that constructs a homeomorphic image of a graph to solve the problem of routing according to the cutting plan, solves this problem, and interprets the solution results.