Properties Of Cutting Tools Research Articles

Boosting Projections to improve surface roughness prediction in high-torque milling operations

Industrial solutions for surface roughness prediction are in great demand, especially in high-torque milling operations, owing to the exponential expansion of wind power energy generation over the past decade. In this paper, we use Boosting Projections to predict surface roughness in high-torque, high-power face milling operations. A data set is generated from experiments performed under industrial conditions, using a milling machine with a high working volume, to train and validate the new algorithm. The experimental data comprise a very extensive set of parameters that influence surface roughness: cutting tool properties, machining parameters and cutting phenomena. The proposed method is based on non-linear boosting projections (although it uses linear projections to speed up the training process). To the best of our knowledge this is the first time it has been used in an industrial context. It demonstrates a higher prediction accuracy when compared with single multilayer perceptrons, decision trees and classical ensemble methods.

Increasing of cutting efficiency of heat-treated steel through the application of cutting tools of high-strength composite ceramic with coating E. S. Sotova, M. N. Lazareva

In the paper there is investigated the cutting tool properties of high-strength composite ceramics with multi-coated cutting hardened steel. Mathematical models of cutting are obtained. They establish the dependence of the wear and tear on the back of the instrument, roughness of the machined surface of the parts, the tangent component of the cutting forces, as well as cutting power on the modes of turning. A problem of cutting tools modes optimization is made of high-strength composite ceramics. It is established that the application of the multi-functional coatings on ceramic cutting tool allows you to increase the efficiency of processing.

Computer aided cutting process parameter selection for high speed milling

High speed milling (HSM) is one of the emerging cutting process having tremendous potential not only in increased metal removal rates but also in improved surface finish, burr free edges, dimensional accuracy and a virtually stress free component after machining. Defining high speed machining sometimes is controversial, since the actual cutting speed that can be achieved depends on the workpiece material, the type of cutting operation and the cutting tool material used. The full understanding of this technology requires a structured process model to describe the high speed milling process which allows for the prediction of process output parameters. The paper focuses on generating a computer model of modular structure complete with an integrated input parameter database for high speed milling based on theoretical considerations. This model is applied to analyse published data and it was revealed that these results were controversial with regards to machinability indicators, e.g. cutting force, energy, temperature and the like. Therefore the research has been extended to the experimental measurement and analysis of cutting forces, and removal rates with particular consideration being given to workpiece and cutting tool properties. The results obtained from these experiments correlate well with the process parameters predicted by the computer model. The developed computer model allows for process parameter selection of HSM process relevant to the aerospace industry, but the considerations can be extended to the milling of difficult-to-machine materials.

Optimization of cutting tool properties through the development of alumina cermet

As a means of optimizing the wear resistance and the toughness of cutting tools, alumina cermet tools have been developed, characterized and tested at high cutting speeds. These tools combine the chemical stability afforded by metal oxides and the toughness imparted by metal binders. Alumina is bound to nickel through zirconia by reacting alumina with a Ni-Zr alloy. The wear properties of these tools were characterized by cutting heattreated AISI 4340 steel at speeds ranging from 3 to 15.2 m s −1, feed rates of 0.13 – 0.28 mm rev −1 and depths of cut of 1.27 – 2.54 mm. Tests indicate that its wear resistance is comparable with that of pure alumina tools but that its toughness is greater.