Edge Preparation Research Articles

Estimation of Drag Finishing Abrasive Effect for Cutting Edge Preparation in Broaching Tool.

In recent years, cutting edge preparation became a topic of high interest in the manufacturing industry because of the important role it plays in the performance of the cutting tool. This paper describes the use of the drag finishing DF cutting edge preparation process on the cutting tool for the broaching process. The main process parameters were manipulated and analyzed, as well as their influence on the cutting edge rounding, material remove rate MRR, and surface quality/roughness (Ra, Rz). In parallel, a repeatability and reproducibility R&R analysis and cutting edge radius re prediction were performed using machine learning by an artificial neural network ANN. The results achieved indicate that the influencing factors on re, MRR, and roughness, in order of importance, are drag depth, drag time, mixing percentage, and grain size, respectively. The reproducibility accuracy of re is reliable compared to traditional processes, such as brushing and blasting. The prediction accuracy of the re of preparation with ANN is observed in the low training and prediction errors 1.22% and 0.77%, respectively, evidencing the effectiveness of the algorithm. Finally, it is demonstrated that the DF has reliable feasibility in the application of edge preparation on broaching tools under controlled conditions.

Comparative Microstructural, Mechanical and Corrosion Study between Dissimilar ATIG and Conventional TIG Weldments of 316L Stainless Steel and Mild Steel

Stainless steels and mild steels are widespread materials in several industries. The dissimilar welding of materials is a technique used to meet the needs of various industries. Mild steel and 316L austenitic stainless steel have different chemical compositions and thermal and mechanical properties. Therefore, it would be interesting to develop a flux paste that would ensure the reliability and sustainability of welded structures made of dissimilar materials. In this work, pseudo-component fluxes were analyzed regarding the resulting weld aspects, microstructures, mechanical properties and corrosion resistance of dissimilar 316L austenitic stainless steel and mild steel welded joints. Using a mixing design available in Minitab 17 software, the obtained optimal pseudo-component flux was composed of 74% SiO2, 3% Fe2O3, 13% Cr2O3 and 10% NaF. During this investigation, the weld carried out using the optimal flux combination with the activated tungsten inert gas (ATIG) technique was evaluated and compared to another weld executed using the conventional tungsten inert gas (TIG) process. In conclusion, we observed that the optimal flux combination used in the ATIG weld had beneficial effects on the mechanical properties without degrading corrosion resistance when compared to the conventional TIG weld. Moreover, in the ATIG process, the weld depth was achieved in a single pass, while edge preparation or the addition of a filler metal was not required.

Selected properties of RAMOR 500 steel welded joints by hybrid PTA-MAG

The paper describes the selected properties of RAMOR 500 anti-ballistic (martensitic structure in the initial state) high yield strength steel (1450 MPa) welded joints produced by the hybrid PTA-MAG (Plasma Transferred Arc - Metal Active Gas) method. The welded elements were metal sheets 6.7 mm thick in a rectangular shape with dimensions of 200 mm x 350 mm. The tested butt weld joints have been made with process parameters selected according to criterion of lowest level of material weakening in the heat-affected zone (HAZ). The results of metallographic research of welds heat affected zone and base material, hardness distribution and XRD patterns of specific areas have been presented. Depth-sensing indentation (DSI) is used in this work to determine the distribution of mechanical properties affected by annealing/tempering by thermal cycle of hybrid PTA-MAG welding process. The investigation results show that the use of hybrid PTA-MAG heat source for welding of martensitic structure steel makes it possible to use high strength steel filler material (yield strength 890 MPa) without of cold cracks high risk. The hybrid plasma based welding method has a potential to become a beneficial alternative to other welding processes for ballistic protection steel due to its high efficiency, reduced amount of weld metal content or limited requirements for a preparation of edges of welded joints. The weakest area of welded joints is part of HAZ located close to the base material which has been secondarily tempered by heat of welding thermal cycle. The heat input about 0,57 kJ/mm required to achieve full penetration butt welded joints with no defects and with wide enough capillary channel to cover the welding gap during welding process. Hardness decrease in that area is about 25% in relation of base material. The width of the softened zone was approx. 4.5 mm.

Analysis of the grinding wheel wear and machining result during cutting edge preparation with elastic bonded grinding wheels

Cutting edge preparation can be considered as one of the most effective methods for optimizing the cutting tool life and the machining result. In this article, a preparation technique using elastic bonded superabrasive grinding wheels is applied. This method proved to be highly flexible in terms of the achievable cutting edge geometry. However, very little knowledge exists about the grinding wheel wear behavior and therefore the process reliability during cutting edge preparation. In this article, the impact of the process kinematics and parameters on the grinding wheel wear and preparation result is investigated and discussed. For this purpose, the impact of the depth of cut (20, 40 and 60 μm) was investigated, because it serves as the major setting parameter for the size of the cutting edge rounding. However, it also impacts the contact conditions and thermo-mechanical loads in the grinding wheel. The experimental results show that this preparation method achieves a high preparation accuracy and repeatability at small and medium depths of cut (20 and 40 μm). For a depth of cut of 60 μm, the preparation result became more inappropriate (increased deviation of the cutting edge shape from an ideal radius) with an increasing number of prepared cutting edges. Here, the soft grinding wheel exhibited a higher process stability in terms of repeatable machining results. The machining results correspond to the experimental findings from the grinding wheel radial wear Δrs. At a depth of cut of 20 and 40 μm, the grinding wheel radial wear for the hard bond was lower than for the soft bond. At a depth of cut of 60 μm, the grinding wheel radial wear for the hard bond exceeds the value for the soft bond by 10%. However, the grinding (G) ratios for the hard bond were higher for all investigated depths of cut. The highest difference was observed at a depth of cut of 20 μm. Here, the G ratio for the soft grinding wheel was 7.92 and for the hard one 18.53. Furthermore, an application scenario was introduced using suitable dressing cycles, so that up to 138,000 cutting edges (equals 34,500 indexable inserts) could be prepared with one grinding wheel using this preparation technique in industrial tool manufacturing applications.

Analysis of abrasives on cutting edge preparation by drag finishing

Cutting edge preparation has become more important for tool performance. The micro-shape, radius and surface topography of the cutting edge play a significant role in the machining process. The cutting edge of solid carbide end mills has some micro-defects after grinding. For eliminating aforementioned problem, this study investigates drag finishing (DF) preparation for solid carbide end mills to reconstruct cutting edge micro-geometry. This paper is to present the design of DF experimental setup and analyze the characterization of various abrasive media (K3/600, K3/400, HSC 1/300 and HSO 1/100) on the evolution of the surface/roughness along the cutting edge. In parallel, the mechanism of material removal and the kinematics trajectory of the drag finishing are presented. In fact, the form factor (also called as “K-factor”) of the cutting edge micro-geometry is quantified. Comparing with four lapping media, the higher material removal rate (MRR) and the lower surface roughness are obtained by HSO 1/100 abrasive process. The results show that the cutting edge K-factor, MRR and surface topography are influenced by the abrasive particles size, composition and process time.

Experimental analysis of the impact of an artificially generated tool wear pattern on the residual stress induced by 15-5PH steel turning

Finish turning is one of the key operations governing the residual stress of functional surfaces. The residual stress state is determined by the cutting conditions and the selected cutting tool system (macro geometry, cutting edge preparation, tool substrate, multi-layer coating…). However, this initial configuration evolves over time due to tool wear. Therefore, it seems very instructive to reproduce the wear process of the tool in order to understand the evolution of thermo-mechanical loadings applied to the machined surface. Flank wear is a parameter which can be difficult to fully control, and it is complex to reproduce experimentally. In this work, a simple, controlled and repeatable method of producing a known flank wear state is introduced and the impact of the flank wear on the surface integrity is assessed. This involves two parts, first reproducing a given flank wear state and second, evaluating experimentally the residual stress induced by the flank wear state on the workpiece. Carbide tools are used to turn 15-5PH steel under dry conditions. It is shown that the method produces consistent results. The effect of flank wear on residual stress is most notable and can generate data to validate numerical modelling. Areas for improving the method are also discussed.

Mathematical Modelling to predict dilution in MIG welded aluminium 8011 plates

During MIG (Metal Inert Gas) welding, mixing of the base metal with the filler metal deposited onto the weld causes a change in the composition of the weld metal called as dilution which generally is undesirable. The degree of dilution depends on the type of joint and joint edge preparation, the welding process, process parameters, and the technique used. The purpose of this study is to look at the effects of different input parameters on dilution in MIG welding. 5 mm thick 8011 grade aluminum plates were used for this experiment and using the statistical technique of design of experiments, a mathematical model to relate dilution to various input factors is built. The dilution is calculated by taking the ratio of penetration area to the total area of the weld bead. To create the design matrix for the trials, the central composite rotatable design (CCRD) is employed. With the help of Response Surface Methodology (RSM), the findings are graphically examined. The developed model is employed to optimize the input parameters in order to achieve the lowest possible dilution.

Study on magnetic preparation of dual disk based on silica gel magneto-elastic abrasive particles

Magneto-elastic abrasive grains have magnetism, low elastic modulus and excellent abrasive performance, and have the characteristics of bonded abrasive grains and loose abrasive grains. The dual-disk magnetic preparation greatly improves the preparation quality and efficiency. Firstly, the magneto-elastic abrasive particles are introduced into the edge preparation of the dual-disk magnetic tool, and the preparation method of 4035 silica gel magneto-elastic abrasive particles is proposed. According to the microscopic characteristics of the magneto-elastic abrasive particles, the finite element software ABAQUS is used to establish the magneto-elastic abrasive particles. The meso-level representative volume element (RVE) model is built to analyze the stress and strain law of magneto-elastic abrasive particles under tension and compression. Secondly, an experimental platform for magnetic preparation of magneto-elastic abrasive particles with dual disks was built to analyze the force of magneto-elastic abrasive particles. Finally, Through the magnetic preparation experiment of the magneto-elastic abrasive dual-disk magnetic force, the influence of the disk rotation speed, abrasive particle size and relative magnetic permeability on the cutting edge wear is studied. And compared to the magnetic abrasive particles double-disk magnetic and drag finishing method, the magneto-elastic abrasive particle double-disk magnetic preparation method can obtain the maximum edge wear amount and the maximum surface roughness decreasing amplitude. The research results are of great significance to promote the progress of our country's magnetic high-efficiency processing and magneto-finishing processing technology.

Success of Feather Margin Preparation for Full Metal Prosthodontic Crowns in the Canine Teeth in 84 Pet and Working Dogs (2005-2017).

Medical and dental records of Veterinary Dental Specialties and Oral Surgery were searched to identify dogs that received full metal prosthodontic crowns on canine teeth, using a feather or knife edge preparation between 2005 and 2017. A total of 160 teeth in 84 dogs were included in the study. Current follow-up by telephone, electronic mail, or electronic messaging was conducted, in addition to thorough record review for in-person recheck examinations. Treatment was considered successful if the prosthodontic crown was in place and no further or additional injury to the tooth had occurred at the time of reexamination, owner contact, or patient death. Tooth fracture apical to the prosthodontic crown occurred in 2 (1.25%) cases, bond failure between the tooth and the cement or the cement and the crown occurred in a single case (0.625%), and one metal crown required replacement after 3 years due to wear (0.625%), for an overall failure rate of 2.5%. These results suggest that feather preparation of the margin is at least as, if not more, successful as the more commonly accepted and performed chamfer margin, and thus is a successful, practical and durable option for prosthodontic crown treatment in dog canine teeth.

Investigation of the gap bridgeability at high-power laser hybrid welding of plasma-cut thick mild steels with AC magnetic support

One of the challenges of the high-power hybrid laser welding of thick steels is the sensitivity of the process of the process to manufacturing tolerances. This usually leads to a time-consuming preparation of the welding edges, such as milling. The study deals with the influence of the edge quality of milled and plasma-cut steel made of S355J2 with a wall thickness of 20 mm on the laser hybrid welded seam quality. Furthermore, the gap bridgeability and the tolerances towards edge misalignment was investigated. An AC magnet was used as backing support to prevent sagging and positioned under the workpiece, to generate an upwards directed electromagnetic pressure. The profiles of the edges and the gap on the top and root side were measured using a digital camera. Single-pass laser hybrid welds of plasma-cut edges could be welded using a laser beam power of just 13.7 kW. A gap bridgeability up to 2 mm and misalignment of edges up to 2 mm could be achieved successful. Additionally, the independence of the cutting side and the welding side was shown, so that samples were welded to the opposite side to their cutting. For evaluation of internal defects or irregularities, X-ray images were carried out. Charpy impact strength tests were performed to determine the toughness of the welds.

COMPARISON OF PREPARATION METHODS IN TERMS OF TOOL LIFE AND SURFACE ROUGHNESS

The article compares two cutting edge preparation methods and their influence on the machined surface roughness of the difficult to cut nickel alloy Inconel 718 and the tool wear of cutting inserts made of cemented carbide. The manufacturing and preparation process of cutting inserts used in the experiment were made by Dormer Pramet. The preparation methods used in the experiment were drag finishing and brushing. Cutting parameters did not change during the whole turning process to maintain the same conditions in each step of the process and were determined based on tests for a semi-finishing operation of the turning process. To obtain durability of 25 to 30 minutes with controlled development of the tool wear the cutting parameters were determined with cooperation with the cutting inserts manufacturer.

Experiment and Modeling of Milling Force Based on Tool Edge Preparation

Experiment and Modeling of Milling Force Based on Tool Edge Preparation

Microstructure and properties of Ti–6Al–4V alloy welded joint by keyhole gas tungsten arc welding

In this paper, 12 mm Ti6Al4V titanium was successfully welded in a single pass using the keyhole gas tungsten arc welding technology, without special edge preparation or the addition of a filler material. The microstructure and properties of the welded joint are studied. The microstructure of the joint was classified and characterized in detail according to the difference of the effect of welding thermal cycle, and the difference of the top, middle and bottom microstructure of the joint was compared and analyzed. The microhardness of transverse joint fluctuates in the range of 50HV0.2. The difference of longitudinal microhardness is about 100HV0.2. The lowest is 280 HV0.2, and the highest is 378 HV0.2. The tensile strength of the joint reaches 925 MPa. The fracture position of the joint is located in the base metal. The Charpy impact energy of the weld center reaches 50J, which is 56% higher than that of the base metal 32J, and the weld metal shows good toughness.

Influence of End Mill Manufacturing on Cutting Edge Quality and Wear Behavior

One of the decisive factors for the performance of milling tools is the quality of the cutting edge. The latter results from the process control of the individual steps along the tool manufacturing process chain, which generally includes the sintering or pressing of the blanks, grinding, cutting edge preparation, and coating of the tools. However, the targeted and application-specific design of the process steps in terms of high economic efficiency is currently limited by a lack of knowledge regarding the influence of the corresponding process parameters on the resulting cutting edge quality. In addition, there is a lack of suitable parameters that adequately represent the characteristics of the cutting edge microtopography. This publication therefore investigates the influence of manufacturing processes on cutting edge quality and wear behavior of end mills. On this basis, different characterization parameters for the cutting edge quality are derived and evaluated with regard to their ability to predict the wear behavior.

Technology and equipment for friction stir preweld edge preparation

Introduction. Friction stir welding is widely used due to certain advantages of this method. Factors that reduce the strength of joints made of high-strength aluminum alloys are considered. When welding flat sheets, an effective way to increase the strength of the weld is edge thickening. The paper proposes a method for such thickening. A device is developed, calculations and experiments are carried out. Materials and Methods. Laboratory equipment has been developed to provide simultaneous thickening of two edges to be welded. The main component of this equipment is a steel roller, which is rolled along the edges of two blanks and thickens them due to plastic deformation. The same setup can be used for the friction stir welding process. To calculate the geometry of the thickened edges and the parameters of the deforming roller depending on the value of the edge settlement, a mathematical model based on the contact problem for elastic (roller) and elastoplastic (blank) bodies with a bilinear hardening law has been developed. A three-dimensional simplified geometric model of the facility with account of its symmetry has been constructed. On the contact surfaces, special contact finite elements were selected and the finite element mesh was refined. The numerical implementation of the model was carried out in the ANSYS package. Results. The theoretical model provides assessing the stress-strain state of interacting elements. On the basis of the developed finite element model, the parameters of the thickened edges are calculated, and the geometry of the thickened edges is defined. Using the developed laboratory equipment, full-scale experiments on thickening the edges of the blanks were carried out. The experimental results confirm the adequacy of the developed theoretical model and calculations based on it. The possibility of adjusting the size of the thickened edges is shown. Discussion and Conclusion. A technology for obtaining thickened edges in places of welds is proposed. It will reduce the metal consumption of structures and ensure the bearing capacity of welded joints not lower than similar characteristics of the base metal. A theoretical model of the process is developed, and a numerical experiment providing the selection of the process parameters is carried out.

Individual decisions drive the changes in movement patterns of ground beetles between forestry management types

Moving from one habitat to another, the dispersal of individuals has consequences for their conditions, population dynamics and gene flow. Our major motivation was to explore the effects of different forestry treatments, such as preparation (partial) cuts and clear cuts, on the selected population of the forest ground beetle, Carabus coriaceus (Coleoptera: Carabidae). We tagged six individuals (three males and three females) with small radio-transmitters and each was released in the treatment habitat core, at the edges and in the core of control forests respectively. The recorded trajectories were divided into two major movement phases: a random walk and a directional movement using hidden Markov models. Our results revealed that in the core zone of preparation cuts, the random walk and the directional movement were equally distributed in the trajectory. A clear directional movement was observed in the clear cuts suggesting the beetles moved directly toward the adjacent (control) forest interior. The trajectories at the edges of both treatments were dominated by the random walk and so for the controls. These results suggest that forest ground beetles can avoid the forestry treatments especially clear cuts, however edge habitats and (the studied) preparation cuts can mitigate the migration constraints due to their more favorable environmental conditions compared to clear cuts.

Improvements of hybrid laser arc welding for shipbuilding T-joints with 2F position of 8 mm thick steel

One of the main concerns in the early stages of manufacturing flat units of shipbuilding is to ensure the quality of the joints throughout the structure. The flat units are constituted by butt welded flat plates, on which longitudinal T-welded reinforcements are placed to rigidize the structure. Among the different welding technologies, Hybrid Laser Arc Welding (HLAW) is becoming a mature process, profitable and highly productive. In addition, more innovative welding equipment are being developed nowadays, offering greater work flexibility, and raising expectations of achieving better quality, and economic viability. Another key point of HLAW to keep in mind is that structural distortions are reduced, resulting in decreasing the cost and time of straightening work.In the present contribution, the influence of HLAW parameters on the quality of fillet joints of naval steel has been analysed. Experimental HLAW tests were performed with a high power disk laser to join EH36 naval steel plates, with a T configuration. The influence of different processing parameters has been analysed, as the laser power, welding speed, wire feed rate and the configuration of the HLAW processes (including head angle and laser/arc leading process). In addition, FEM simulations were carried out in order to estimate residual stresses and distortion of welded part. The distortion values provided by FEM presented excellent agreement with the measured experimental results. To evaluate the welds, non destructive tests including X-ray tests, metallographic analysis of cross sections, and microhardness mapping tests were performed.Full penetration 8 mm T welds were obtained for the first time at an industrially applicable 2F position with a reasonable HLAW head angle, in one single step without sealing root, and using zero gap square groove edge preparation. The present contribution presents welding rates up to 2.2 m/min for 2F T-joints of this steel thickness, a much higher processing velocity than previously reported for industrial applications.

Development of a welded structure and a technology for manufacturing a smoke valve casing ID 2000 for use in a blast furnace

The aim of this work is to develop a welded structure and a technology for manufacturing a smoke valve casing ID 2000 for use in a blast furnace to substitute the previously used cast design from 35L steel. The proposed large-size structure (3742 x 3020 x 3275 mm) should provide a strong and tight connection of three thick-walled (to 40 mm) rolled shells. The development of the structure and its elements was carried out using three-dimensional modelling in the Compass-3d software. The joining zones of the shells are designed as bent transition elements with a double curvature. It was found that the use of technological allowances when bending the cylindrical shells of sectors makes it possible to obtain parts with the required accuracy (a deviation in diameter not higher than 5 mm). The rolling of the shells having a complex curved line of joining can be performed on a rectangular workpiece. A curved joining line with the sections having a length of 150-170 mm and cross-connections of 50-70 mm is cut out on the workpiece using a computerized flame-cutting machine. It was shown that the removal of the cross-connections by manual gas cutting and preparation of edges for welding can be performed only after rolling and welding of the straight joint of the shell. Techniques for fitting the double-curved segments during assembling using special hydraulic struts were elaborated. These techniques were used to develop a technology for manufacturing a welded casing structure. Due to the optimization of the casing design, its weight was reduced by 5.5% compared to that produced by casting. Using the developed technology, two valves were manufactured to replace obsolete valves at the largest blast furnace (5500 m3) in Europe "Severyanka", PJSC Severstal. The described technical solutions provided a significant reduction in the labour intensity of manufacturing the presented structure, at the same time as ensuring its high quality and optimized weight compared to that produced by casting.

Influence of tool edge form factor and cutting parameters on milling performance

Tool edge preparation can improve the tool life, as well as cutting performance and machined surface quality, meeting the requirements of high-speed and high-efficiency cutting. In general, prepared tool edges could be divided into symmetric or asymmetric edges. In the present study, the cemented carbide tools were initially edge prepared through drag finishing. The simulation model of the carbide cemented tool milling steel was established through Deform software. Effects of edge form factor, spindle speed, feed per tooth, axial, and radial cutting depth on the cutting force, the tool wear, the cutting temperature, and the surface quality were investigated through the orthogonal cutting simulation. The simulated cutting force results were compared to the results obtained from the orthogonal milling experiment through the dynamometer Kistler, which verified the simulation model correctness. The obtained results provided a basis for edge preparation effect along with high-speed and high effective cutting machining comprehension.

WITHDRAWN: Experimental study on behaviour of cold-formed steel built-up beams with welded connections

The exploratory study of comparison of flexural behaviour of the cold formed steel built-up section with varying pitch between the welded connections are tested and studied. The built-up sections made with two channel sections (connected back-to-back) are used in the present investigation. The pitch between the welding are 100 mm, 150 mm, 200 mm, and 250 mm. Resistant spot welding is used for the connection. Resistant spot welding is used for the highly uniform joints and there is no need for edge preparation. The flexural behaviour of bolted formed built-up section is also investigated and compared with welded built-up sections. The behaviour of beams with welded connections are compared with the beams connected with 10 mm diameter bolts with 100 mm pitch and 30 mm edge distance.