Effect Of Tool Geometry Research Articles

The effects of tool geometry on static strength and the failure mode in micro-friction stir spot welding

The effects of tool geometry on static strength and the failure mode in micro-friction stir spot welding

Development of an analytical model to investigate the effect of tool geometry and cutting parameters on the milling performance of Inconel 718

This research proposes a new analytical method to predict cutting forces of end milling considering various tool geometry and cutting parameters, aiming to achieve enhanced stability in machining processes and superior quality in machined surfaces. The end-milling process was modeled using the unequal shear zone theory of oblique cutting, where the helical cutting edges were discretized into multiple oblique cutting edges, and the coordinate transformation method was employed to analyze the geometric and force relationships among them. Then, the influence of helix angles on cutting force, machined surface quality, tool life, and wear patterns in the milling process of Inconel 718 was investigated. These findings provide valuable insights that can be utilized to optimize the design of variable helix tools.

Friction stir processing of AA6061-T6/graphene nanocomposites: Unraveling the influence of tool geometry, rotation, and advancing speed on microstructure and mechanical properties

This research investigated the effect of tool geometry, rotation, and advancing speed on the microstructure and mechanical properties of aluminum AA6061-T6/graphene nanocomposites fabricated by friction stir processing (FSP) using three conical tools with the pin cone angles (PCAs) of 2, 2.5, and 3°. In the first step of the study, the process was performed with and without graphene nanoplatelets (GNPs) at different rotations (710, 1120, and 1400 rpm) and advancing speeds (80, 125, and 160 mm/min). The yield strength, tensile strength, and microhardness of all the samples were lower than those of the base metal. In the second step of the study, the heat input was controlled by reducing rotations (112, 180, and 280 rpm) and advancing speeds (31.5, 25, and 20 mm/min). The mechanical properties of processed samples were studied by tensile tests and microhardness measurements. Microstructural evolution in samples was analyzed by means of a field emission scanning electron microscope (FESEM) equipped with an X-ray energy dispersive spectrometer (EDS) and electron back-scattered diffraction (EBSD) detector. The results indicated that the mechanical properties were improved in the second step with the increase in the advance per revolution (APR) and the PCA. This was linked to the microstructure evolution in the processed samples affected by process parameters and regulated heat input. The effect of each input variable on the mechanical properties was evaluated by statistical analysis and was validated by analysis of variance (ANOVA). The optimal processing was attained by utilization of PCA, tool rotation, and advancing speed.

Investigating nano-SiC reinforced WE43 magnesium matrix surface composites

Abstract Magnesium matrix surface composites have been garnering attention due to their superior mechanical and corrosion resistance properties. An idea of facile fabrication of surface composite composed of nano-SiC reinforced WE43 matrix through friction stir processing was explored in this study. Also, the effects of tool geometries, tool rotations, and tool feeds on resultant properties were comprehensively investigated. Uniform dispersion of SiC nanoparticles within stir zone was evident. Square tool demonstrated the most promising results. Processing at 1700 rev min−1 and 60 mm min−1 with a square tool produced finest grains in surface composites exhibited exceptional microhardness (180.8 HV), nanohardness (1.867 GPa), elastic modulus (41.69 GPa), and wear resistance (0.0254 mm3 min−1). Besides it, WE43 substrates also exhibited superior mechanical properties when processed with a square tool at 800 rev min−1 and 60 mm min−1. This research opens up new possibilities for the development of reliable magnesium matrix surface composites for multifunctional applications.

Experimental investigation on effect of tool geometry on thermal and crystallization characteristics in drilling of carbon fiber reinforced PEEK composite

AbstractThis paper comprehensively investigated the effect of the tool geometries on heat transfer and special crystallization characteristics in the drilling of carbon fiber‐reinforced polyetheretherketone (CF/PEEK) composite for the first time. Three tools with different geometries (twist, brad, and dagger drill) are carried out on CF/PEEK drilling experiments, and temperature, as well as crystallinity and surface roughness, are introduced to make a comparative evaluation on the effect of the tool geometries. The results show that the drilling temperature is determined by the contact length of the profile between the drill and the material. Correspondingly, better surface quality with lower surface roughness and smoother surface is obtained by using a twist drill due to the heat‐induced PEEK smearing effect. Further, in situ XRD and differential scanning calorimeter (DSC) were used to characterize the crystallization characteristics where crystal phase transformation at different temperatures was measured. The occurring temperature of the strongest crystallization characteristics for CF/PEEK is basically not affected by tool geometries, all at 300°C, and the limiting crystallization temperature is 344.5 ± 0.7°C. The crystallinity is found to be affected by drilling temperature and cooling rate and gradually decreases along the heat transfer direction. This work provides a new sight into the improvement of CF/PEEK drilling.Highlights The effect of tool geometries on thermal and crystallization for CF/PEEK is provided. In situ XRD and DSC are used to characterize crystallization characteristics. The drilling temperature and cooling rate are both determinants of crystallinity. The limiting crystallization temperature of the CF/PEEK composite is 344.5 ± 0.7°C. Heat‐induced PEEK smearing effect improves the surface quality of CF/PEEK drilling.

Experimental Investigation on the Effects of Tool Geometry and Cutting Conditions on Machining Behavior during Edge Finishing of Granite Using Concave and Chamfered Profiling Tools.

Granite edge finishing through grinding is a common process in the granite processing industry, crucial for achieving the final desired shape and edge quality of products. This study focuses on the granite industry, specifically delving into the significance of grinding and polishing for improving aesthetics and extending material longevity. The experimental design entails a comprehensive factorial experiment plan involving two workpiece materials (white and black granite samples) and two cutting tool edge shapes (chamfer and concave), each with two grit sizes: G150 and G600. The cutting conditions varied and consisted of variations in spindle speeds (1500, 2500, 3500 rpm), feed rates (500, 1000, 1500 mm/min), and lubrication modes (wet/dry). The results uncover intricate relationships among these parameters and part quality, underscoring the pivotal role of tool geometry in achieving superior surface finishes and in controlling the cutting forces. These findings contribute to a nuanced understanding of the dynamic interplay between tool characteristics, material properties, and machining conditions within the granite industry.

Effect of Tool Geometry on the Microstructure of Friction Stir Welding of Copper and 316L Stainless Steel

The microstructure evolution during dissimilar friction stir welding of copper with stainless steel 316L is studied. The welding is performed in transparence configuration using tools of two different geometries. The joints are characterized by optical microscopy, scanning and transmission electron microscopy, electron backscattered diffraction, and microhardness. The microstructure and crystallographic texture of base metals are significantly affected. The joint produced using a shoulder of 8 mm in diameter is characterized by a copper nugget with refined grains. The texture of copper is dominated by component of the shear texture. The steel beneath the tool shows a grain refinement with grains of sub‐micron size and a texture which is close to the ideal simple shear texture. For the joint produced by the 16 mm diameter tool shoulder, the nugget consists of large grains of copper, while the steel beneath the tool shows small recrystallized grains of micrometer size. The texture in the steel is dominated by the component of the shear texture. The Cu/316L interface in both types of joint is of very good quality. In a detailed study of the interface, it is revealed that the welding of metals is achieved by mutual intense mechanical interlocking without formation of any intermetallic compounds.

Performance analysis of conventional and high-feed turning tools in machining the thermally affected zone after plasma arc cutting of low carbon manganese-alloyed steel

The service life of cutting tools significantly affects machining costs. Establishing end-of-life criteria is crucial to mitigate wear effects on part quality, machine integrity, and maximize tool utilization. This is particularly important in machining operations with materials featuring numerous surface defects, as observed in those processed by prior thermal cutting operations, leading to accelerated tool wear rates. This study compares tool life and wear mechanisms in conventional and high-feed turning of low carbon manganese-alloyed steel bushes, previously profiled by plasma thermal cutting. Machinability tests utilized Class P carbide tools with triangular geometry for conventional turning and rhombic geometry for high-feed turning, both coated for enhanced performance. Tool's end-of-life criterion was established per ISO 3685 standard. The machining parameters adopted include a standard cutting depth of 1.5 mm, varying cutting speeds (140, 160, and 200 m/min) and feed rates (0.2; 0.3; 0.4 mm/rev for conventional turning, and 0.5; 0.75; 0.82 mm/rev for high-feed turning). Analysis involved assessing tool wear rates by observing flank wear and analyzing it using scanning electron microscopy and energy-dispersive spectroscopy techniques. Machined surface quality was quantified by roughness measurements. Metallographic characterization of bushes post-cutting indicated thermal cutting effects on the cutting edge's microstructure, microhardness, and residual stress. Machinability test results showed superior wear resistance in the high-feed turning tool (wear rate about 13 % lower). Surface finish evaluation demonstrated that, when isolating the effects of tool geometry and feed rate, the average surface roughness increased at a similar rate with tool wear for both conventional turning and high-feed turning. Identical wear mechanisms were observed: abrasive on the flank and adhesive on the rake face. Thus, the superiority of high-feed turning over conventional turning is established under the evaluated machining conditions.

Effects of Tool Geometry and Fluid on the Surface Morphology and Integrity in Scratching TiMMCs

Effects of Tool Geometry and Fluid on the Surface Morphology and Integrity in Scratching TiMMCs

Microstructural and corrosion behaviours of dissimilar friction stir welded aluminium alloys

In this study, the friction stir welding (FSW) process was employed to investigate the effect of tool geometry on the corrosion behaviour and microstructure of friction stir welded AA7075-7651 and AA1200-H19 using Central Composite Design. The workpieces were machined and welded, and the interfaces were milled. A 2-level full factorial experimental design was deployed using Response Surface Methodology (RSM). A rotational speed of 1500 rpm, welding speed of 30, 60, and 90 mm/min, and a 2° tilt angle of the tool with a plunge force of 7 kN were utilized. The results show that regardless of the tool geometry, multi-response optimum weldment can be achieved at 60 mm/min welding speed and a tilt angle. The microstructure of the optimal weldments presents an ‘onion ring’ pattern, indicating proper mixing of the alloys during FSW. Analysis of the corrosion behaviour revealed a decrease in the polarization resistance when the transverse speed increased from 30 to 90 mm/min, as polarization resistance has a direct relationship with corrosion rate. It can be concluded that FSW ensures excellent weldment, as evident in the microstructural evolution of the resulting weldments, and that tool geometry plays a significant role in the corrosion inhibition efficiency of the alloys.

Influences of tool tip geometry on surface/subsurface damage formation in nanoscratching of single-crystal 4H-SiC

Creating a smooth surface finish with nanometer-scale roughness on SiC is extremely difficult due to its hard, brittle properties and crystal anisotropy. In this study, nanoscratching tests were performed on single-crystal 4H-SiC along various crystal directions by using a sharp Berkovich tip (radius ~150 nm) and a blunt spherical tip (radius ~1 μm), respectively, to reveal the effects of tool geometry on its surface integrity. Results indicate that, under the same load conditions, the Berkovich face-forward tip produced the greatest penetration depth, followed by the Berkovich edge-forward tip and the spherical tip. The extent of surface and subsurface damage caused by the three tips follows the same trend as the penetration depth. Phase transformation did not occur in the scratched surface with the three tips, while it was occurred in the chips generated with Berkovich face-forward tip. The critical load for surface crack formation was larger when scratching along <01−10> directions compared to scratching along <11−20> directions, independent of tool geometry. Microcrack-like defects may form in the subsurface even the surface is free of damage. The microcracks were caused by {01−11} pyramidal <a> and <a+c> slip and by {11−22} pyramidal <c+a> slip when scratching along <11−20> and <01−10> directions, respectively.

Effect of pre-stress on surface integrity in micro milling: Modelling and experimentation

Recent years have witnessed rapid growth in microscale manufacturing, particularly in the biomedical, electronics and aerospace industries. Therefore, it is required to improve the capabilities of micro-cutting processes such as micro-milling to generate intricate features with high surface quality. The surface integrity of the machined materials is influenced by the cutting conditions, tool geometry and material properties. The novelty of the proposed work is to improve the surface finish and compressive residual stress of the milled slot by tailoring the pre-compressive stress condition. Ultrasonic-assisted abrasive peening is used to tailor the residual stress and obtained grain refinement on the surface. The micro-milling is performed on the peened surface of Ti-6Al-4V, Al-6061, and OFHC-Cu to investigate the surface roughness and residual stress. A hybrid model is developed to estimate the surface roughness considering the effect of tool geometry, process parameters, size effect and workpiece microstructure. Induced residual stress at the machined surface is simulated through the finite element (FE) method. Moreover, the FE model simulated the minimal chip thickness and contact pressure at the flank face and is deployed as an input to the analytical model for estimation of surface roughness. The pre-deformed material by peening reduced the surface roughness by 35 to 42 % on different materials and improved compressive residual stress due to grain refinement. The predicted average surface roughness and residual stress are validated with experimental results.

Mechanical behavior of AA5083/AA6061 friction stir welds using modal analysis

Abstract Solid-state joining is used for welding similar or dissimilar materials due to its many advantages like avoiding fusion and formation of a thick intermetallic layer, etc. Determination of the right process parameters (feed rate and rotation speed) and tool geometry (shoulder and pin) is of critical importance in friction stir welding in order to achieve adequate weld quality. The experiments were performed using three process parameters: feed rate (mm min−1), rotation speed (rpm) and pin geometry for friction stir welding of Al5083 and Al6061. Eighteen experiments were performed with different process parameters and mechanical tests (microhardness and tensile measurements) have been carried out to determine the weld quality. Results showed that the best results of ultimate strength (198.5 MPa) were achieved by the triangle pin geometry, 1250 rpm rotation speed and 100 mm min−1 feed rate. Similar results were observed in microhardness tests. Effects of tool geometry, feed rate, and rotation speed on the vibration properties and weld quality are also investigated experimentally. The effects of the FSW parameters used were assessed using vibration analysis.

Recent research progress on various cooling and lubrication techniques used in sustainable hard machining: A comprehensive review

In recent research, hard machining is an essential manufacturing technology to meet the demand for various industrial product quality and precision. Several key issues like higher heat generation, higher tool wear, higher cutting force and inappropriate surface quality were found in hard machining. Researchers have examined several hard machining-related issues and developed their own suggestions for solutions. It was attempted to research the effects of tool geometry, tool materials and coatings, cutting parameters, and different cooling strategies (coolant and its delivery techniques) on various machinability responses, such as tool wear, tool life, cutting forces, surface roughness, chip morphology etc. In this review article, the different methodologies of cooling and lubrication utilized during hard machining processes have been analysed and their potential application towards sustainable machining is explored. This paper addressed the needs, challenges, and trends towards achieving sustainable hard machining of hard-to-cut materials through the application of dry, minimum quantity lubrication, cryogenic and nanofluids-assisted minimum quantity lubrication cooling strategies. It will be helpful to achieve environmental, economical, ecological and societal benefits to justify sustainable machining. Minimum quantity lubrication hard machining and nano-cutting fluid-assisted minimum quantity lubrication hard machining for sustainability will be immensely beneficial for the replacement of traditional cooling strategies for machining hard-to-cut hardened steel. Furthermore, different computational methods adopted in hard machining for optimization and modelling were also explored to get the optimal solution for industrial applications.

Neuro-fuzzy assessment of machined wood fibre–reinforced magnesium oxide composite

ABSTRACT High quality processing key to improving product quality and enterprise benefits. In this work, an adaptive network–based fuzzy inference system (ANFIS) was combined with milling experiments to understand the effects of tool geometry and milling parameters on the surface quality of wood fibre–reinforced magnesium oxide composite (WRMC). Specifically, changes in surface roughness (Ra) and damage of WRMC at different milling conditions were assessed using ANFIS and micro-analysis methods. Development of ANFIS models were confirmed to be reliable for predicting surface roughness. Changes in surface roughness at different milling conditions were determined, and the lowest surface roughness was obtained at the highest rake angle, highest cutting speed, and smallest milling depth. Furthermore, pitting-type damage irregularly distributed on the machined surface is attributed to the pulling out and debonding of wood fibres. Overall, high cutting speed, shallow cutting depth, and high rake angle is recommended for fine machining of WRMC where a smooth surface is desired. This study showcases how neuro-fuzzy models can be combined with conventional micro-analysis to optimize milling parameters for WRMC to minimize surface damage, and paves the way for future studies to optimize cutting tool life and energy consumption.

Analysis of the effect of tool geometry on the cutting process of polycrystalline Fe-Cr-W alloy based on molecular dynamics simulation

In order to study the influence of tool geometry on the machining mechanism of alloy tool steel in the process of ultra precision turning, the polycrystalline molecular dynamics model of alloy tool steel is established with Fe, Cr and W, and the molecular dynamics model of tool is established with B and N. Four potential energy functions, Tersoff, EAM, Morse and L-J, are used to characterize the interaction between atoms in the model. The effects of tool geometry on hydrostatic stress, cutting force, cutting temperature and amorphous atoms in the turning process are analyzed. Research indicates:(1) Hydrostatic stress is mainly concentrated in the contact position between the tool tip and the workpiece, and it is compressive stress; (2) Cutting forces fluctuate and are significantly affected by tool geometry; (3) The cutting heat of about 1000K is concentrated in the chip, and the tool clearance angle has a great influence on the cutting temperature. (4) Amorphous atoms are formed at the chip location and the machined surface, and eventually turn into chips and the metamorphic layer of the machined surface.

Correction to: Effect of tool geometry and cutting parameters on surface quality and chip morphology of amorphous electroless nickel‑phosphorus alloy in ultra‑precision turning

Correction to: Effect of tool geometry and cutting parameters on surface quality and chip morphology of amorphous electroless nickel‑phosphorus alloy in ultra‑precision turning

Effect of tool geometry and cutting parameters on surface quality and chip morphology of amorphous electroless nickel-phosphorus alloy in ultra-precision turning

Effect of tool geometry and cutting parameters on surface quality and chip morphology of amorphous electroless nickel-phosphorus alloy in ultra-precision turning

Investigation of the drilling performance and residual tensile behavior of polyetherketoneketone plates

Due to the excellent properties of PEEK and their widely applications in medical industry, it is necessary to conduct a comparative study into the drilling performance and residual tensile behavior of PEEK plates under varying cutting conditions. In this study, the effects of tool geometry, drilling parameters, and slope angles on the thrust force, tool temperature, hole quality are discussed. The residual tensile behavior of the drilled PEEK plates is elucidated in terms of the full-field strain evolution during tensile testing by the Digital Image Correction system. The results showed that drilling parameter and tool geometry affect significantly cutting forces, tool temperature, and resulting hole quality. The relationship between the machinability and the residual tensile property of PEEK is reported for the first time. Full-field strains during tensile testing are sensitive to the level of drilling-induced damages, which have an impact on the residual tensile property of PEEK components.

Machining Properties of Stone‐Plastic Composite Based on an Empirically Validated Finite Element Method

High‐cutting performance is an essential metric for improving the suitability of materials for industrial applications. Herein, the machining properties of stone‐plastic composite are assessed through a finite element method to explore orthogonal cutting behavior by diamond cutters. The key aspects examined in this work are the effects of tool geometry and cutting parameters on the cutting force, temperature, chip formation, von Mises stress, and surface quality finish. Primary findings show that chip continuity increases proportionally with increase in rake angle but decreases with cutting speed and depth. Meanwhile, both cutting stability and surface quality are negatively correlated with cutting speed and depth but positively correlated with rake angle. These results support the adoption of cutting conditions using greater rake angle, higher cutting speed, and shallower cutting depth to obtain higher cutting performance, that is, greater cutting stability and surface quality in the finishing machining of stone‐plastic composites.