Solid Carbide Tools Research Articles

Trochoidal Milling Using Indexable Inserts

Solid carbide tools were chiefly used for trochoidal milling in the past. Together with SolidCAM and its iMachining software, Mapal has now shown the highly-efficient machining technology also offers advantages for milling with indexable inserts

Evaluation of tool performance and wear through vibration signature analysis in drilling of IS3048 steel

In this paper, a connection between vibration amplitude and tool wear when drilling of IS3048 steel utilizing different dimensioned tools is dissected through tests. Discriminant features, which are sensitive to drill wear and breakage, were developed. These were discovered to be somewhat impervious toward sensor location and cutting conditions. In the process, the vibration amplitude features a checking highlight dependent on ascertaining both the tools and their performance over vibrations, which was discovered to be somewhat powerful for on-line identification of drill tool breakage in both frequency and time domains. These vibrational amplitude signal features are directly affected, related to the tool geometry, which give higher chances of tool selection criteria during the drilling process. The experiments were carried out using solid carbide tool with change in tool geometry under dry conditions where the vibration amplitude for both is evaluated. The results revealed that cutting tool vibrational amplitude and tool wear were relatively dependent showing the tool selection of suitable tool geometry.

Al7129 Metal matrix enhanced with Titanium carbide (TiC) and Boron carbide(B4C) optimized machining parameters utilizing Taguchi method for Surface roughness

The influence of spindle speed, feed rate, and depth of cut of alumina particle on lowering surface roughness during turning of Al7129/TiC/B4C hybrid composite is investigated in this study. The composite is turned using a TiN coated solid carbide tool. Taguchi's experimental design concept is utilized to optimize three tiers of design parameters for improved for better surface finish. The results of the experiments and the microstructure of the machined surface demonstrate that the samples with the lowest feed rate perform better in terms of surface roughness. Surface roughness is also influenced by the wt% of alumina, which is followed by spindle speed when spinning the produced samples.

Analysis of Solid Carbide Drilling Performance on AISI 316L Austenite Stainless Steel using MQL (Minimum Quantity Lubrication) using Peck Drilling Approach

Minimum Quantity Lubrication (MQL) minimizes refrigerants and lubricants mixed with air to foster environmental sustainability. Austenitic AISI 316L stainless steel is often used for the aviation, biomedical equipment and food appliances. However, low machinability of this material makes it difficult to cut resulting low hole surface quality. The objective of the study is to evaluate the drill performance of solid carbide tools while drilling AISI 316L austenite stainless steel and to study the effect of drilling parameters, cutting speed (Vc), feed rate (Fr) and drill geometry (point angle) on tool life, surface integrity and holes accuracy. Solid carbide drilling performance analysis on AISI 316L Austenite Stainless Steel using MQL was assessed in terms of tool life, surface roughness, and hole accuracy. Investigation for optimal conditions of cutting speed, feed rate and point of angle when drilling AISI 316L austenite stainless steel would obtain the optimum output indicates longer tool life, better surface roughness and adequate accuracy in high-speed machining conditions. This MQL oil-air flow is accurately measured and sent to the drill tool edge. The cutting speeds applied for the machining process are 100m / min, 130m / min and 150m / min. For feed rate parameters, the selected values are 0.05mm / rev, 0.1mm / rev and 0.15mm / rev. Rotational drill angles are 110 °, 120 ° and 130 °. The peck drilling investigation is performed on high-speed milling machines keenly will provide guidance to produce good and optimal machining settings of cutting speed, feed rate and angle point to others when they want to drill a hole.

Investigating the effect of cutting conditions and tool geometry on surface roughness in dry end milling of Inconel 625 using TiAlSiN ultra hard coated solid carbide tool

ABSTRACT In aerospace and submarine industries, mechanical parts are designed & developed using nickel-based alloys, such as Inconel 625. In such applications, severe work hardening occurs, leading to poor surface quality. In this context, this study was conducted using an end mill with PVD TiAlSiN coating, under dry conditions, wherein four input variables were considered. Rotatable CCD technique of DoE was used to conduct the experimental plan. RSM was applied to develop a second-order mathematical model, with roughness parameter and process parameters to establish the relationship between them. ANOVA was carried out to test the significance of the model. From the model, it was observed that both the feed per tooth and radial depth of cut have a significant effect on surface roughness. Further, the interaction between the cutting speed and feed per tooth was also found significant. The study also demonstrated that the coated carbide tool has the potential to eliminate the usage of cutting fluid, thus taking care of the environmental concerns, as far as machining operations are concerned.

Application of Taguchi Technique to Optimize the Shoulder Milling Machining Parameters of Aa6063 T6 Aluminium Alloy

In order to minimize surface roughness, in this paper Taguchi technique is being used for optimizing the shoulder milling process parameters. The shoulder milling was done on VMC milling machine on AA6063 T6 by using M series solid carbide tool. There are following cutting parameters like coolant, speed, feed and depth of cut were considered and the level of these parameters were three except the coolant at two level was considered. The experiments was conducted by using L 18 orthogonal array. Signal to noise ratio were calculated for finding the effects of shoulder milling parameters on surface roughness. And analysis of variance was used for finding the contribution of each parameters. The validation of experimental results was done by the confirmation test. Levels of shoulder milling machining parameters to minimize surface roughness were A 1 B 1 C 2 D 2 i.e. coolant on with a feed of 200 mm/min, depth of cut of 0.25 mm and speed is at 5800 rpm. ANOVA table represented the parameters which mostly affected the surface roughness with 40.18% contribution of feed rate which is maximum followed by speed (21.90.%), depth of cut (16.48%), and affect of coolant 0.81%) is insignificant. The study also shows that this method can effectively improve the surface finish of the shoulder milling process.

Optimization of Cutting Parameters Based on Surface Roughness and Cutting Force During End Milling of Nimonic C-263 Alloy

The surface integrity of machined surfaces greatly influences the functional properties of the components such as fatigue life, etc. Nickel-based superalloy such as Nimonic C-263 is termed as difficult to machine material due to its unique properties as well as high strength at elevated temperatures. This study intends to optimize the cutting parameters (cutting speed, feed, depth of cut) during the end milling of Nimonic C-263 and the machining has been carried out using solid tungsten carbide tool coated with TiAlN and Vertical Machining Center. Experimentation is carried out using Taguchi L9 orthogonal array technique and based on signal to noise ratio data, optimum machining parameters were achieved for preferred observable characteristics such as cutting force and surface roughness. Additionally, Multi-purpose optimization (Grey analysis) of the observable characteristics was conducted to predict the optimum machining parameters combination which offers better producible surface finish and lowest cutting force requirement. Further, the analysis of variance (ANOVA) reveals that the feed rate is the farthest influencing factor followed by the depth of cut, cutting speed, and the variations in cutting force and surface roughness are confirmed through chip morphology using Scanning electron microscopy.

A modified analytical cutting force prediction model under the tool crater wear effect in end milling Ti6Al4V with solid carbide tool

This paper presents a study of the relationship between cutting force and tool crater wear of solid carbide tool during milling Ti6Al4V. The cutting force model in milling considering tool crater wear is discussed, which shows that for given the cutting conditions, tool geometries, and workpiece material, cutting force under the tool crater wear effect could be predicted easily and conveniently. The tool wear condition in milling Ti6Al4V is obtained by finite element simulation method. In addition, the experimental work of end milling Ti6Al4V with solid carbide tool is developed. Comparisons among experiment results, mathematical model results, and finite element simulation model results, including cutting force and tool wear, are discussed. The results show that the proposed mathematical model could predict cutting force under the tool crater wear effect with higher accuracy.

FEM based mathematical modelling of thrust force during drilling of Al7075-T6

Like most machining processes, drilling is affected by many parameters such as the tool diameter, the cutting speed and feed. The current research investigates the possibility of developing a finite element modelling based prediction model for the generated thrust force during drilling of Al7075-T6 with solid carbide tools. A total of 27 drilling experiments were carried out in order to examine the interaction between three key parameters and their effect on thrust force. In addition, simulations of the experiments were realized with the use of DEFORM3D™ software in order to obtain the necessary numerical data. Finally, a comparison was made between the experimental and the numerical results to verify that reliable modelling is feasible. The mathematical model was acquired with the use of response surface methodology and the verification of the adequacy of the model was performed through an analysis of variance. The majority of the simulations yielded results in agreement with the experimental results at around 95% and the derived model offered an accuracy of 5.9%.

Influence of machining parameters on the response variable during drilling of the hybrid laminate

ABSTRACT Hybrid laminates made of Carbon Fibre and Glass Fibre Reinforcement have become widely popular in various applications which are mainly due to their excellent structural strength coupled with lower cost. In all these applications, drilling plays a crucial role during the assembly of these structural components. This paper deals with the examination of the influencing parameters (feed rate, tool material) on thrust force during drilling of hybrid laminates. Statistical Design of Experiments has been used for the analysis of the drilling parameters on the thrust force. Taguchi’s L9 (32) array has been used to determine whether the response function is minimised by feed rate or tool material. Hole drilling on hybrid FRP laminate has been done using Solid Tungsten Carbide and High-Speed Steel tool material under controlled machining operations. The results reveal that the tool material has a higher influential effect on the thrust force when compared with the feed rate. Also, the morphology of hybrid laminate was obtained using a Scanning Electron Microscope (SEM) and the results indicate that surface texture was observed to be optimum.

Semi-analytic modelling of cutting forces in micro ball-end milling of NAK80 steel with wear-varying cutting edge and associated nonlinear process characteristics

Cutting edge of miniature ball-end mill is one of decisive importance for the machining performance by affecting the thermal and mechanical load in cutting process. In this paper, a semi-analytic model is proposed to estimate the cutting forces in micro ball-end milling of NAK80 steel considering wear-varying cutting edge and the associated nonlinear process characteristics. The wear-varying cutting edge geometry under the different wear stage is obtained by 3D optical profilometer. The measured results indicate that cutting edge of miniature ball-end mill under the different wear stage includes not only the enlarged cutting edge radius but also the extended flank wear land, which can be described by a combination of edge radius and flank wear land width. The influence laws of the edge radius and flank wear land width on tangential and feed force coefficients are investigated, and the enlarged edge radius and extended flank wear land under different wear stage could be separated from each other by utilizing the cutting force coefficients data based on their different sensitivity on cutting forces. A semi-analytic method is developed to predict the shearing/plowing/friction forces in primary and tertiary shear zones based on classical oblique cutting and slip-line field model. The nonlinear tool-chip friction behavior with the phenomenon that the ratio of tool-chip contact length to uncut chip thickness and friction factor nonlinearly change with the ratio of uncut chip thickness to edge radius are investigated and employed to estimate rake/shear/friction angles, and the nonlinear strain gradient plasticity effect with the fact that effective strain gradient is affected by not only rake angle and shear angle, but also primary shear zone thickness that obviously increases with reduce of the ratio of uncut chip thickness to edge radius are considered to estimate the shear flow stress. The nonlinear behavior derived from the tool-chip/workpiece friction and material constitutive affects the contribution level of size effect on cutting forces in micro ball-end milling. Finally, to calibrate and validate the effectiveness of the proposed cutting forces model, a set of micro ball-end milling of NAK80 steel experiments are performed on a three axis ultra-precision machine by using same solid carbide tool with wear-varying cutting edge under different wear stage. The comparisons between the predicted and measured results show that the proposed model can provide higher accuracy and better understanding for micro ball-end milling of NAK80 steel.

Evaluation of Desirability Function Approach and Genetic Algorithm optimization of drilling characteristics on Duplex 2205

Abstract This work deals with the development of an empirical model using Response Surface Methodology (RSM) for the independent parameters of drilling operation using Duplex 2205 using solid carbide tool in the CNC milling machine. The considered independent variables are spindle speed, feed rate and dependent variables are drilling time, entry burr height, entry burr thickness, exit burr height, exit burr thickness, surface roughness. After successful development of an empirical model, the process parameters are optimized with two different techniques named Desirability Function Approach (DFA) and Genetic Algorithm (GA). The spindle speed and feed rate were optimized as 270 rpm and 0.073 mm/rev. respectively through DFA and 468.85715 rpm and 0.13684 mm/rev., respectively through GA to minimize the responses. Later, the evaluation made between the optimization techniques to achieve the best responses which emphasize the superiority of GA over DFA.

EVALUATION OF CHIP MORPHOLOGY WHEN DRILLING TITANIUM ALLOY

Chip formation within a hole making processes plays an important role in selection of proper machining parameters. Understanding of this phenomenon is also important in relation to wear behaviour or machined surface integrity parameters like roughness, residual stresses and many others. Proposed study aims to compare different shapes and forms of chips produced when drilling titanium alloy Ti-6Al-4V with solid carbide tool by various cutting conditions. The effect of cutting edge radius and side clearance angle on chip formation process was also considered within this work. Experimental data has confirmed strong relationship between drilling parameters and evaluated variable.

Investigation of the Impact of Cutting Parameters on Surface Integrity in the End Milling of Inconel 625

Nickel based super alloys, such as Inconel 625 is amongst the most difficult to machine, due to its low thermal conductivity and high strength at higher temperature. Although, they are used in aerospace exhaust systems and other applications, the strain hardening that results during the machining operation, which adversely affects surface integrity of machined surface of such materials especially in extensive applications, is a cause for concern. In this context, this study was carried out, involving the milling operation, using solid carbide tools coated with TiAlSiN, under specifically developed conditions for dry machining of the difficult to cut materials. The cutting parameters were 4 in number, namely radial rake angle, feed per tooth, cutting speed and radial depth of cut and the response parameters included surface integrity characteristics, such as residual stresses, surface roughness and micro-hardness. Based on the experimental analyses, it was found that the micro-hardness of machined surface was higher. Micro hardness of sub surface decreases with the depth (50,100,150,250μm) due to a reduction in the work hardening of the Inconel 625, underneath the surface layer. The residual stresses were analyzed using main effect plot, and it was seen that the residual stresses were significantly influenced by the radial rake angle, followed by feed per tooth.

Drilling of CFRP/Ti Stacks in Wet and Cryogenic Condition

This paper studies the effects of cryogenic liquid nitrogen compared with conventional wet coolant in drilling of CFRP/Ti using diamond-like carbon coated solid carbide tools. The experimental investigation was carried out taking into account the influence of main process parameters and adopting different strategies in the two different materials. The influence of the two different cooling conditions on tool wear was investigated through the comparison of the thrust force and torque; the effect on the hole quality was analysed through the measurements of burr height and diameters. The use of a cryogenic coolant results in both lower thrust force and torque but in a slightly poorer quality of the holes.

Prediction of surface quality and optimization of process parameters in drilling of Delrin using neural network

The high-temperature polymers like Acetal homopolymer (Delrin) currently have a wide variety of use. They are quite often utilized in traditional components to reduce weight, cost or meet a specific application requirement, and so on. Some of preferred uses of such polymers include aircraft interiors, wire insulation, wire couplings and fixtures, and so on, particularly at high-temperature applications. The machining process like drilling may affect the near net shape of the final product. This experimental study is done through modeling and optimization for identifying the suitable tool and optimum parameters for drilling of Delrin polymer under dry conditions to achieve high surface finish. The three levels of parameters such as spindle speed ( N), feed rate ( f), and tool point angle ( Θ) are taken as control parameters of the response variable. Two different commercially available tool materials namely high-speed steel drill tool and solid carbide tool are accounted in experiments. L27 orthogonal array is initially taken for the experimentation in CNC turning center with horizontal drilling setup. Artificial neural network is employed to sample, train, and test the input parameters in order to lessen the experimental error and measurement error of response variables. Response surface models are developed and optimal parameters toward the surface quality of the hole are determined through the desirability function approach. It is found that the surface generated under dry mode with speed of 1026 r/min, feed of 0.1 mm/min, point angle of 118° recorded the surface roughness of 0.699 µm, which is considered to be the best for drilling Delrin material.

Hybrid cryogenic MQL for improving tool life in machining of Ti-6Al-4V titanium alloy

It is estimated that there is a need for 37,000 new passenger aircrafts until 2037. About 15% of the modern aircrafts are made of titanium alloys due to their high strength to weight ratio. In typical aerospace manufacturing, there is a buy-to-fly ratio of 6:1 for titanium parts which indicates significant machining requirements. Machining titanium alloys is generally associated with short tool life, poor surface integrity, low productivity and high manufacturing costs. These issues have made Ti-6Al-4V a difficult to machine material.In this study, a new hybrid cryogenic MQL cooling/lubrication technique is proposed for end milling Ti-6Al-4V using coated solid carbide tools. The effect of the proposed system on machinability of Ti-6Al-4V was studied at various cutting speeds and compared with flood, minimum quantity lubrication (MQL) and cryogenic cooling. Tool life, tool wear and surface roughness were thoroughly investigated as key machinability metrices and a new model for tool life based on tool wear is proposed. The analysis indicates a significant shift in CNC milling performance, as the new hybrid cryogenic MQL technique shows an increased tool life of 30 times is achieved together with a 50% improvement in productivity compared to state-of-the-art flood coolant machining.

Tool wear processes in low frequency vibration assisted drilling of CFRP/Ti6Al4V stacks with forced air-cooling

Drilling CFRP/Ti6Al4V stacks in one-shot time becomes essential in the modern aerospace manufacturing sectors in order to guarantee the productivity due to the demands of riveting and fastening assembly. In the present study, a novel integrated system of low frequency vibration assisted drilling (LFVAD) coupled with the forced air-cooling was designed to investigate the tool wear issues in drilling of CFRP/Ti6Al4V stacks. The used uncoated solid tungsten carbide tools were specially designed with threaded shanks for fitting the adapter of the LFVAD tool holder. Main geometrical features of the threaded shank drills include a 6.35 mm diameter, a 140° point angle, a 30° helix angle and two cutting edges. Drilling temperatures and forces were in-situ measured for the LFVAD subjected to varying conditions, and the results were compared with the conventional drilling under the identical drilling conditions. It is found that the small titanium chip segments produced by the interrupted cut of vibration drilling can be removed efficiently via the help of the forced air-cooling. Compared with the conventional drilling, slower flank wear rates and lower cutting temperatures are identified under the LFVAD with the forced air-cooling. The adhesive wear is the main wear mode for both drilling methods; however, the chemical wear becomes more pronounced while the cutting edge chipping predominates in the LFVAD. In sum, the LFVAD with the forced air-cooling is confirmed capable of improving the machinability of the CFRP/Ti6Al4V stacks from the aspects of reducing tool wear.

Wear behavior of TiAlN coated WC tool during micro end milling of Ti-6Al-4V and analysis of surface roughness

The demand for high quality micro components has been on the upsurge for the past few decades. Nowadays micro end milling is preferred to produce 3D micro parts. This paper presents an investigation on wear behavior of solid tungsten carbide (WC) tool with TiAlN coating during micro end milling of Ti-6Al-4V. Miniaturization of the tool combined with machining of hard to machine material like Ti-6Al-4V results in rapid tool wear. Feed/tooth to tool edge radius ratio (f/r) has got significant influence on micro end milling machining mechanism. For f/r less than one, ploughing is dominant, and the shearing mechanism prevails when f/r is greater than one. Therefore, experiments were carried out at two feed rates 0.3 µm/tooth and 5 µm/tooth to examine the effect of tool edge radius on tool wear. Tool wear in terms of flank wear, adhesive wear, abrasive wear, enlargement of tool edge radius, and delamination of coating was studied, and an investigation on the effect of tool wear on surface roughness was also carried out. A 3D optical profilometer was used to characterize tool wear and surface finish of the machined feature. With 0.3 µm/tooth feed rate, tool fails after ~700 mm length of cut and with 5 µm/tooth feed rate, tool fails after ~1000 mm length of cut. For both 0.3 µm/tooth and 5 µm/tooth feed rates tool fail approximately at 15–20 µm flank wear width. Adhesive wear was found to be the major tool failure mechanism for both feed rates. Moreover, in micro end milling operation selecting a feed rate slightly above the tool cutting edge radius will be beneficial so that a good surface finish is obtained during initial stages of the wear.

Innovative method for cutting edge preparation with flexible diamond tools

The micro geometry of the cutting edge is of central importance for the performance of cutting tools. It influences all essential parameters in the machining process: chip formation, thermal and mechanical load on the tool and the workpiece, tool wear and the resulting workpiece quality. The effect depends on the size and shape of the cutting edge rounding. Depending on the machining process, asymmetrical roundings often show the greatest potential. In addition to increasing tool life, the quality of the surfaces produced can be improved by a specifically designed asymmetrical rounding. For edge preparation, blasting, brushing and drag finishing are used in industrial applications. However, an economic production of asymmetrical cutting edge geometries on cutting tools with complicated cutting edge geometry, such as solid carbide tools with helical cutting edge, cannot be achieved with these methods. Therefore, a novel method for preparation of the cutting edge rounding using flexible bond diamond polishing tools is introduced. Hence, the conducted research in this study analyzes the basic mechanisms and influencing factors using the new preparation method. For this purpose, polishing tests are carried out on carbide indexable inserts. The results show that the polishing tools can be used to create both asymmetrical and symmetrical roundings in an industrially relevant dimension.