Minimum Tool Wear Research Articles

Study on tool wear for mircomilling of 6061 aluminium alloy

Tool wear is one of the key points of studies onmicromilling, which affects tool durability and milling efficiency. In this paper, the two-flute cemented carbide end mills with coating TiAlN are used to conduct the experimental studies on the tool wear inmicromilling process for 6061 aluminium alloy material. The wear form and wear mechanism of tools are analyzed. The influence sequence of key parameters on tool wear and the optimized parameters combination are obtained by the orthogonal experiment results analyses. The results show that whenmicromilling 6061 aluminium alloy, the main wear forms of the tools are coating peeling and tip breakage, and the wear mechanism is adhesive wear. The significance order of key milling parameters for the wear band width of the side edge from large to s mall is radial depth of cut ae, feed per tooth fz and axial depth of cut ap. The optimized parameters combination which can obtain the minimize tool wear is ae = 300 μm, fz = 1 μm and ap = 150 μm. In actual machining, the tool life can be improved by selecting suitable processing parameters. The results of this study can be used as a reference for the selection of parameters inmicromilling.

EDM of Ti-6Al-4V: Electrode and polarity selection for minimum tool wear rate and overcut

ABSTRACTTitanium and its alloys especially Ti-6Al-4V are being widely used numerous application areas. In addition to have iconic properties, Ti-6Al-4V is considered as challenging material in machining perspective that is why it has captured global research focus. In this research, electric discharge machining of Ti-6Al-4V has been carried out by employing four different types of electrode materials (graphite, aluminum, copper, and brass) assigned with two alternate polarities (positive and negative). Selection of the most appropriate tool material and electrode polarity is the important aspect needed to be explored for this alloy. In addition to polarity, discharge current, and pulse time ratio have been considered as process variables owing to have their direct influence in electric discharge machining. Taguchi L9 array has been employed for each of the four electrodes with positive polarity and similarly L9 with negative polarity. Thus, a total number of 72 experiments have been conducted. Tool wear rate and overcut (OC) around the machined surfaces are the response characteristics to be investigated in order to achieve minimum amounts of both of these two responses. Selection of the most suitable tool with common tool polarity has been carried out meeting the decision criteria of minimum tool wear and minimum OC.

Performance evaluation of coated carbide tool during face milling of AISI 304 under different cutting environments

Stainless steel 304 (AISI 304), having wide industrial applications, exhibits poor machinability because of rapid work hardening and poor thermal conductivity. Therefore, cutting fluids are utilized to remove heat and provide lubrication in the machining zone, but their application pose serious environmental and health hazards, calling to minimize their use for green machining. Nano fluid minimum quantity lubrication (NMQL) technique provides an effective alternative to flooded cooling. Current study evaluates performance of NMQL in terms of tool wear and surface finish during face milling of AISI 304 steel. To enhance thermal conductivity of MQL, soluble multi walled carbon nano tubes (1% wt) were mixed in vegetable oil (cutting fluid). Cutting parameters were optimized to minimize tool wear and surface roughness and validation test also conducted under dry, flooded and pure MQL conditions to compare their performance with NMQL machining. Results revealed superiority of NMQL machining over dry, flooded and pure MQL conditions by 7.45%, 2.08% and 5.15% respectively, in terms of tool wear and 54.10%, 34.43% and 39.34 respectively, in terms of surface finish. Wear characterization of tools indicated less adhesion and abrasion marks on tool flank face during NMQL machining compared to dry and flood conditions.

Optimization Milling Process When Machining C45 Steel by Ball Nose Mill for Minimum Tool Wear using Taguchi Method

In this paper, Taguchi method with L16 was used to experimental research in order to present the influence of cutting parameters and feed way on the tool wear when machining C45 by ball nose mill. The experimental result shows the influence of above parameters on tool wear and the value of cutting parameters and feed way for minimum of tool wear.

Machining and Characterization of Channels and Textures on Quartz Glass Using μ-ECDM Process

Applications of various glass materials like sodalime, borosilicate and pyrex are growing in the field of micro-electro mechanical systems. Quartz glass composes of pure silicon dioxide which is well- known for its hardness and processing of it would widen the scope of its application in product miniaturization. Micro-Electro Chemical Discharge Machining (μ-ECDM) is a non-conventional hybrid technique which combines the features of Electro Chemical Machining (ECM) and Electro Discharge Machining (EDM). In the present paper, channels are machined using μ-ECDM on 4 mm thick quartz glass with 370 μm diameter stainless steel (SS) tool. Experiments are designed at various levels of voltage (V), electrolyte concentration (wt%C) and duty factor (%DF) for parametric study. Signal to Noise (S/N) ratio and Grey Relational Analysis (GRA) are used to optimize the process parameters to enhance responses individually and simultaneously. The obtained S/N ratio optimized parameters to maximize Material Removal Rate (MRR) are - 60 V, 30 wt%C, 60 %DF resulted in 753 μg/min, to minimize Tool Wear Rate (TWR) are – 40 V, 20 wt%C, 50 %DF resulted in 2.99 μg/min and to minimize width of the channel are- 40 V, 20 wt%C, 60 %DF resulted in 500 μm. The GRA optimized parameters are- 40 V, 20 wt%C and 50 %DF resulting in 81 μg/m of MRR, 2.99 μg/m of TWR and 557.6 μm of width with entropy technique- equal weightage. Further an attempt has been made to machine texture on the quartz surface which is still in its early stages of research. GRA optimized parameters as detailed above are used to machine channels and generate textures of 45° hatch, square hatch and 45° criss-cross hatch on quartz glass.

Tool wear and surface roughness analysis in milling with ceramic tools of Waspaloy: a comparison of machining performance with different cooling methods

Ceramic cutting tools are widely used particularly in high-speed machining of difficult-to-machine materials. However, using cutting fluid with these ceramic tools significantly reduces tool life. Therefore, the inclusion of a cooling/lubrication method into the process to improve the machining performance of ceramic tools will make machining efficiency much more effective. The aim of this study is to analyze the effect of cutting parameters and cooling/lubricating conditions on tool wear and surface roughness in the milling of nickel-based Waspaloy with ceramic tools. The cutting tools selected for the study were Ti[C, N]-mixed alumina inserts (CC650), SiC whisker-reinforced alumina inserts (CC670) and alumina and SiAlON ceramic inserts (CC6060). The machining parameters comprised three different cooling/lubricating methods (dry, wet and MQL), three different cutting speeds (500, 600 and 700 m/min) and three different feed rates (0.02, 0.04 and 0.06 mm/rev). Analysis of variance was used to determine the effects of the machining parameters on tool wear and surface roughness. In addition, a regression analysis was conducted to identify the relationship between the dependent and independent variables. According to the experimental results, the minimum quantity lubrication method was identified as the best cooling method for minimum tool wear and surface roughness. In terms of ceramic grades, the SiAlON inserts provided better results in all experimental trials. The dominant wear types observed in all cutting tools were flank wear and notch wear.

A Recent Investigations: Effect of Surface Grinding on CFRP using Rotary Ultrasonic Machining

Abstract The industrial scenario demands the product to be produced in higher surface finish with minimum tool wear. Grinding is predominantly known to provide excellent surface finish among other machining processes. The scope for improvement is always exists in the processes. In the meantime, Material Removal Rate (MRR) of the procedure ought not to be affected. Since, it directly affects the productivity of the process. The composite Carbon Fibre Reinforced Plastic (CFRP) has preferred properties involving high strength-over weight extent, high shortcoming restriction, high modulus-to-weight extent, etc. Due to the non-uniform and varying in magnitude, high gratings /abrasiveness and high strength ability of the reinforcement in CFRP composites, results in difficult to-cut (surface materials) in surface grinding shapes. The conventional surface grinding process on CFRP requires high cutting force at the same time material removal rate is low. In request to decrease and eliminate these intricacies, Rotary Ultrasonic Machining (RUM) is favoured for surface grinding of CFRP composites. In this paper, interdisciplinary reviews on CFRP composites have been done under the reaction of surface grinding of the composite using rotary ultrasonic machining. This paper will give the guidelines to future research in impacts on CFRP under RUM observational studies.

Environment friendly milling of Inconel-625

Inconel 625, having wide industrial applications, exhibits poor machinability because of rapid work hardening and poor thermal conductivity. Therefore, cutting fluids are utilised to remove heat and provide lubrication in the cutting zone, but their application poses serious environmental and health hazards, calling to minimise their use. Multi-walled carbon nanotube (NMQL) technique provides an effective alternative to flooded cooling-machining of Inconel and stainless steel. Current study evaluates performance of NMQL in terms of tool wear and surface finish during face milling of Inconel 625. To enhance thermal conductivity of MQL, soluble multiwalled carbon nanotubes (1% wt.) were mixed in vegetable oil. Cutting parameters were optimised to minimise tool wear and surface roughness and validation tests were also conducted under flooded and dry conditions to compare their performance with NMQL machining. Performance of cutting tool during NMQL machining was found to be 15.56% and 3.45% better than dry and flooded machining respectively, on the basis of tool wear (VB), and was 14.06% and 59.02% improved over flooded and dry machining respectively, in terms of surface roughness (Ra).

Environment friendly milling of Inconel-625

Inconel 625, having wide industrial applications, exhibits poor machinability because of rapid work hardening and poor thermal conductivity. Therefore, cutting fluids are utilised to remove heat and provide lubrication in the cutting zone, but their application poses serious environmental and health hazards, calling to minimise their use. Multi-walled carbon nanotube (NMQL) technique provides an effective alternative to flooded cooling-machining of Inconel and stainless steel. Current study evaluates performance of NMQL in terms of tool wear and surface finish during face milling of Inconel 625. To enhance thermal conductivity of MQL, soluble multiwalled carbon nanotubes (1% wt.) were mixed in vegetable oil. Cutting parameters were optimised to minimise tool wear and surface roughness and validation tests were also conducted under flooded and dry conditions to compare their performance with NMQL machining. Performance of cutting tool during NMQL machining was found to be 15.56% and 3.45% better than dry and flooded machining respectively, on the basis of tool wear (VB), and was 14.06% and 59.02% improved over flooded and dry machining respectively, in terms of surface roughness (Ra).

Multi-response optimization in environment friendly turning of AISI 304 austenitic stainless steel

PurposeThe purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface quality of AISI 304 stainless steel during environment friendly turning under nanofluid minimum quantity lubrication (NMQL) conditions using PVD-coated carbide cutting inserts.Design/methodology/approachTurning experiments are conducted as per the central composite rotatable design under the response surface methodology. ANOVA and regression analysis are employed to examine significant cutting parameters and develop mathematical models for VB (tool flank wear) and Ra (surface roughness). Multi-response desirability optimization approach is used to investigate optimum turning parameters for simultaneously minimizing VB and Ra.FindingsOptimal input turning parameters are observed as follows: cutting speed: 168.06 m/min., feed rate: 0.06 mm/rev. and depth of cut: 0.25 mm with predicted optimal output response factors: VB: 106.864 µm and Ra: 0.571 µm at the 0.753 desirability level. ANOVA test reveals depth of cut and cutting speed-feed rate interaction as statistically significant factors influencing tool flank wear, whereas cutting speed is a dominating factor affecting surface roughness. Confirmation tests show 5.70 and 3.71 percent error between predicted and experimental examined values of VB and Ra, respectively.Research limitations/implicationsAISI 304 is a highly consumed grade of stainless steel in aerospace components, chemical equipment, nuclear industry, pressure vessels, food processing equipment, paper industry, etc. However, AISI 304 stainless steel is considered as a difficult-to-cut material because of its high strength, rapid work hardening and low heat conductivity. This leads to lesser tool life and poor surface finish. Consequently, the optimization of machining parameters is necessary to minimize tool wear and surface roughness. The results obtained in this research can be used as turning database for the above-mentioned industries for attaining a better machined surface quality and tool performance under environment friendly machining conditions.Practical implicationsTurning of AISI 304 stainless steel under NMQL conditions results in environment friendly machining process by maintaining a dry, healthy, clean and pollution free working area.Originality/valueMachining of AISI 304 stainless steel under vegetable oil-based NMQL conditions has not been investigated previously.

Molecular Technology: Materials Innovation (Volume 3)

The foremost aim of Electrical Discharge Machining (EDM) users and manufactures is to obtain a better process stability, maximum productivity, precise and accurate machining of the component with minimum tool wear. For achieving better efficiency in EDM, selection and setting of input parameter is a crucial step. This study investigated the effect of input parameters such as workpiece electrical conductivity, gap current, gap voltage, pulse-on-time and pulse-off-time on the responses namely material removal rate (MRR) and tool wear rate (TWR). Experiments were designed and performed as per the Taguchi’s L18 (61 × 34) array. Taguchi’s approach and utility concept were employed for optimizing conflicting responses. Obtained results showed that the overall utility was significantly affected by gap current, gap voltage, pulse-on-time and pulse-off-time. Thus the obtained optimal values of MRR and TWR are 9.157 mm3/min and 0.128 mm3/min respectively.

Technology-Based Recontouring of Blade Integrated Disks After Weld Repair

The widespread adoption of blade integrated disks (blisks) made of titanium demands tailored regeneration processes to increase sustainability and economic efficiency. High standards regarding geometrical accuracy and functional properties as well as the unique characteristics of each type of damage complicate the repair. Thus, flexible and well-designed processes are necessary. Typically, material deposit is followed by a milling or grinding process to restore the original shape. Here, the individual repair processes not only have to be controlled but also their interaction. For example, depending on the resulting microstructure of the welded seam, the recontouring process needs to be adapted to minimize tool wear as well as shape deviations of the complex blade geometries. In this paper, the process chain for a patch repair is examined, consisting of a tungsten inert gas (TIG) welding process followed by five-axis ball nose end milling. Conventional TIG as well as a modified TIG process producing a finer grain structure and enhanced mechanical properties of deposited material was investigated. Grain refinement was achieved by SiC particles added to the weld pool. Based on the characteristics of the fusion material and static stiffness of the component, a methodology is introduced to minimize shape deviation induced by the subsequent milling process. Special attention is given to tool orientation, which has a significant impact on the kinematics and resulting process forces during milling. An electromagnetic guided machine tool is used for compensation of workpiece deflection.

Multi-characteristics optimization in EDM of NiTi alloy, NiCu alloy and BeCu alloy using Taguchi’s approach and utility concept

The foremost aim of Electrical Discharge Machining (EDM) users and manufactures is to obtain a better process stability, maximum productivity, precise and accurate machining of the component with minimum tool wear. For achieving better efficiency in EDM, selection and setting of input parameter is a crucial step. This study investigated the effect of input parameters such as workpiece electrical conductivity, gap current, gap voltage, pulse-on-time and pulse-off-time on the responses namely material removal rate (MRR) and tool wear rate (TWR). Experiments were designed and performed as per the Taguchi’s L18 (61 × 34) array. Taguchi’s approach and utility concept were employed for optimizing conflicting responses. Obtained results showed that the overall utility was significantly affected by gap current, gap voltage, pulse-on-time and pulse-off-time. Thus the obtained optimal values of MRR and TWR are 9.157 mm3/min and 0.128 mm3/min respectively.

Environment Friendly Machining of Inconel 625 under Nano-Fluid Minimum Quantity Lubrication (NMQL)

Superalloy Inconel 625 although having many industrial applications owing to its high strength, exhibits poor machinability because of its sticky nature and poor heat conductivity. To improve its machinability, use of cutting fluids becomes necessary to remove heat and provide lubrication in the cutting region. However, harmful effects of cutting fluids on environment and operator health restrict their application. Several efforts have been carried out to replace or minimize the quantity of conventional cutting fluids used in machining to strive for green machining and economizing machining operations. Nano-fluid minimum quantity lubrication (NMQL) technique has evolved as best alternative to flood conditions cooling /lubrication especially for machining of alloys like Inconel. This paper experimentally investigates the suitability of NMQL (carbon nanotube; CNT in vegetable oil) in machining of Inconel 625. The objective was to minimize tool wear and surface roughness under different machining conditions. Tool performance in NMQL was also compared with that under dry and flood conditions. The results revealed superiority of NMQL in terms of better tool life and improved surface finish over dry machining and nearly equivalent performance to wet (flood) machining thus provides the way forward for sustainable and environmental friendly machining.

Hard turning of high-carbon high chromium tool steel using CBN tools under different lubricating/cooling conditions

The application of environment-friendly cutting fluid in machining processes can strongly influence the wear on the cutting tools and the surface finish on workpiece materials. This is only possible, when the cutting fluid provides better penetration into the cutting zone, thereby providing a better cooling and lubricating effect. Therefore, this study aims to show the effect of various cutting fluid cooling conditions and machining parameters on tool flank wear (VB) and surface roughness (Ra) of the work piece while turning AISID2 steel with coated CBN tools. By adopting RSM technique with FCCD and using analysis of variance, the effect of cutting parameters on desired outputs was explored. The results showed that machining time was the most dominant parameter influencing both tool wear and surface roughness. Moreover, cutting fluid conditions also showed considerable contribution towards decreasing tool wear rate and increasing surface finish. In addition, the cutting tools were examined under scanning electron microscope (SEM) together with EDS. It was observed that abrasion along with BUE formation were the most dominant wear mechanism modes at low cutting speeds. However, at higher cutting speed and feed combinations, abrasions followed by diffusion and adhesion were the dominant form of wear mechanisms. Suppression of BUE was observed at higher cutting speeds of CBN tools. Finally, desirability function approach (DFA) was used to find out the optimal cutting parameters for minimum tool wear with the maximum surface finish .

Multi-objective optimization of the trimming operation of CFRPs using sensor-fused neural networks and TOPSIS

This work presents the results of an optimization study of trimming carbon fiber composite by technique of order preference by similarity to ideal solution (TOPSIS). Edge trimming was conducted at different levels of cutting speed, feed speed, and radial depth of cut using a 2k factorial design. The effects of cutting parameters on tool wear, surface roughness and tool temperature were analyzed and discussed. Data generalization was performed by training multiple neural network structures (NN) where the input vector of the neural networks contained sensor data in addition to typical process parameters. TOPSIS was used to select the optimal cutting conditions that could generate minimum tool wear, surface roughness, and tool temperature simultaneously while maintaining high production rates. The results show that the NN models offer better results when sensor data is fused in the input vector. TOPSIS optimum conditions were confirmed by validation experiments and were found to be accurate.

Multi-objective optimization of end milling process parameter for stir casted alumina reinforced aluminium metal matrix composite using RSM

Modern manufacturing firms aim to attain quality, dimensional precision, increased production rate, minimal tool wear, economy and mainly surface roughness. Milling is becoming an essential material removal technique can be used for optimizing surface roughness of the composites for micro level and economic performance. Alumina reinforced Aluminium Metal Matrix Composites (AAMMC) developed by the stir casting method gives good mechanical properties and which is also used in many automotive, aerospace and industrial applications. This work focuses on the effect of end milling machining process parameters such ascutting speed, feed rate, depth of cut on machining of stir casted AAMMC. Alumina content of 10wt% is reinforced with Aluminium matrix is used for this research work, it was found that AAMMCs provide higher strength to weight ratio, wear resistance and hardness properties. Optimal levels and important end milling machining parameters were obtained using ANOVA and response surface methodology. The optimal values of surface roughness and the machining time were obtained at Cutting Speed of 1750 rev/min with a feed rate of 0.3 mm/rev and depth of cut 0.2mm. The predicted and measured values were interrelated with each other. This results determined that the model obtained using response surface methodology is utilized to analyse the Surface Roughness S.R and the Machining Time M.T of milling machining of AAMMC.

Optimization of Process Productivity for Multi Phase Carbon Nanotubes (CNT) Reinforced Nanocomposites Using Taguchi-Fuzzy Model

The present work is focused on the processing and machining of multiphase carbon nanotubes reinforced nanocomposites. In this work the author has performed electric discharge machining on multiphase carbon nanotubes reinforced nanocomposites. Optimal combination of different process parameters have been decided determined for maximum material removal rate and minimum tool wear rate which results the improvement in productivity of the complete process. In this study four different process parameters (Peak current, gap voltage, pulse on time and duty cycle) are used and the most significant parameter is illustrated. In the present work, the factor material removal rate has been considered as productivity measure. The goal is to determine the best process condition for maximizing material removal rate and simultaneously for minimizing the tool wear rate values, which may be considered as multi-response optimization problem. Taguchi method is a well known optimization technique used for optimizing the single objective function. Consequently the conversion process of objective functions invites ambiguity, uncertainly etc. into the computation. These implications always arises the need to correlate various responses. Hence to overcome these implications a fuzzy reasoning of multiple performance characteristics has been developed. This results in the transformation of multi performance characteristics in single multi-performance characteristics (Productivity) and can be optimized using Taguchi method. Using Taguchi’s design of experiment methodology optimal combination of process parameters will be obtained for various performance measures. Process productivity Optimize using the Fuzzy logic approach and the optimal results were also validated.

Prediction model for single-point diamond tool-tip wear during machining of optical grade silicon

In this study, the influence of various machining parameters on the diamond tool-tip wear during single-point diamond turning (SPDT) of optical grade silicon was examined. The results from ten face turning experiments conducted with identical diamond inserts are presented. The tool-tip wear was recorded in each trial as a dependent variable of the three varying independent variables, which are cutting speed, feed rate, and depth of cut. The findings indicate that the tool wear was sensitive to a combination of the cutting parameter of low speeds and high feeds. The effect of cutting depth was found to be the least influential. It was further established that the rate of diamond tool-tip wear in face turning of optical grade silicon decreases with decreasing tool-workpiece engagement time per revolution. Experimentally, a combination of high cutting speed and moderate feed rate generated a good surface finish with minimal tool wear. At this combination, diamond turning is conducted with reduced machining time, high rate of production, and a significant reduction in machining cost. Overall, the predominant type of tool wear observed was flank wear with flank wear land characterized by notches, micro-grooves, and micro-chippings. The results further suggest the possibility of prolonging the ductile cutting process by proper selection and control of cutting parameters.

Optimization of Machining Parameters Using Fuzzy Taguchi Method for Reducing Tool Wear

Manufacturing industries are gradually changing to green production due to the increasing production cost. Reducing tool wear in production can not only decrease production cost but also the effect the environment. Thus, it becomes a crucial issue for the machining industry. This study investigates the optimal machining parameters for the computer numerical controlled turning process of S45C steel in minimizing tool wear. The correlation between control parameters (speed, cutting depth, and feed rate) and production quality were constructed by using semantic rules and fuzzy quantification. The Taguchi method was additionally employed to determine the optimal turning parameters. Under the consideration of environmental protection and tool cost, the optimal machining parameters were furthermore derived from the fuzzy semantic rules. The practicability of the optimal parameters was moreover verified through turning experiments. It is found that the proposed method in this study is appropriate and applicable to universal applications.