Terms Of Tool Wear Research Articles

Friction Comparison and Wear Analysis of Ceramic Cutting Tools Made from Alumina-Zirconia- Chromia Content

This research focused on wear analysis by using the coefficient of friction (COF) and high-speed CNC turning machine against ceramic cutting tools made from 80 wt.% Al2O3 - 20 wt.% ZrO2 mixed with 0.2 - 0.8 wt.% Cr2O3. The results showed that the sample with a composition ratio of 80 wt.% Al2O3 – 20 wt.% ZrO2 – 0.6 wt.% Cr2O3 demonstrated the lowest coefficient of friction of 0.305. In terms of tool wear, this cutting tool showed uniform abrasion marks on the flank wear, resulting in 60% - 80% better tool life compared to Al2O3 and Al2O3-ZrO2. Based on the observation by using SEM, analyses showed that grains were tightly bound to each other at a high cutting speed of 350 m/min and with a feed rate of 0.175 mm/rev, compared to Al2O3 and Al2O3- ZrO2 which showed visible chipping and notch. The addition of 0.6 wt.% Cr2O3 on Al2O3-ZrO2 composition was enough to increase the strength and reliability against ceramic cutting tools for machining purposes.

Study on the Current State of Research in the Field of Titanium Aluminides Milling Processes

Recently, there has been a significant interest in the research and industrial application of titanium aluminides. These alloys present great relevance in the aerospace and automotive sectors, where machining processes for the manufacture of high-dimensional precision parts are a fundamental aspect. The interest in the use of these alloys is since they combine a very low density, lower than the Ti6Al4V alloy typically used in these applications, and exceptional mechanical properties at high temperatures. However, titanium aluminides present great difficulties to be machined, being classified as a difficult-to-cut material, as they have high hardness and brittleness, low thermal conductivity, and high chemical reactivity. In the last decade, research on the machining processes of these intermetallic composites has been carried out, although few published works can be found. In particular, research on milling processes is incipient, and further progress is needed in the study and characterization of the process. In this work, a review of the state of the art is carried out to establish the achievements made concerning technological parameters, improvements with the application of sustainable lubrication systems, and the efficiency of the process in terms of tool wear and cutting temperature. In this way, future lines of research in this field would be established. In short, the results obtained aim at a further definition of the tribological system involved in titanium aluminide milling, the use of cryogenic and mixed MQL-cryogenic lubrication, and the definition of tool configurations that allow higher machining speeds to be achieved.

Comprehensive analysis of tool wear, surface roughness and chip morphology in sustainable turning of Inconel-601 alloy

The objective of this research was to explore the impact of various cooling conditions on machinability, as potential alternatives to traditional cooling methods. To achieve this aim, a series of experiments were performed, where dry machining, minimum quantity lubrication (MQL), nanofluids, cryogenic (cryo) cooling, and hybrid cooling (cryo+nano MQL) methods were tested. Under distinct nanofluids conditions hBN(0.2 %) + graphene(0.2 %) performed well and overall cryo+nano MQL produced better result in terms of tool wear, microhardness, surface and chip morphology. The results demonstrated that the cooling effect of the Cryo-MQL regime, which maintains the cutting temperature at a tolerable level and preserves the lubricant performance of the MQL, is the cause of the lowest Vb value of 90 μm.

Influence of crystallographic effect on tool wear, cutting stress, cutting temperature, cutting force and subsurface damage in nano cutting of single crystal silicon carbide

Single crystal 3C-SiC as a typical hard and brittle material. Due to its extremely high hardness and brittleness, diamond tools can have drastic wear problems in a short period of time when performing nano-machining processes. Single-crystal 3C-SiC has good anisotropy. In order to gain insight into the effect of crystal orientation on the tool wear behavior during nano-cutting, this paper investigated the tool wear for six cutting crystals downward using molecular dynamics simulation. The tool wear process was analyzed in terms of tool wear, cutting stress, cutting temperature, cutting force and subsurface damage. The results showed that the tool is subjected to large hydrostatic stress concentrations, radial forces and tool temperature concentrations during machining. Under these effects, abrasive wear, graphitic wear and amorphous phase change were produced. In addition, the clearance face of the tool is more severely worn than the rake face. By reasonably selecting the cutting crystal orientation, well control and improvement of tool wear and machined surface quality can be achieved.

Machinability analysis of Ti-6Al-4V under cryogenic condition

Aerospace alloys are termed as hard to cut materials owing to their low thermal conductivity, high temperature strength and elevated chemical reactivity. Cryogenic conditions can be effectively deployed to improve the machinability and productivity while addressing environmental and sustainability concerns connected with high tool wear and the use of conventional cutting fluids. Current work was undertaken to develop a novel tool wear map under cryogenic condition using cutting speed and feed rate as input variables. The developed map was demarcated into regions of low, moderate and high tool wear zones in addition to an unusually high wear zone, termed as avoidance zone existing between cutting speeds of 65–95 m/min and feed rates of 0.18–0.22 mm/rev. Characterization of developed map in terms of tool chip contact length revealed its direct relationship with cutting speed and feed rate accounting for the formation of different wear regions. Elemental analysis of avoidance zone detected high presence of TiN which results in larger tool chip contact length owing to its higher thermal conductivity. Chip morphology characterization highlighted an increase in chip compression ratio and decrease in shear angle due to the reduction of effective tool rake angle, further elevating the cutting zone temperature promoting wear. SEM and EDS spot analysis indicated the presence of adhesive and diffusion-dissolution wear mechanisms as the tool wear progresses. Comparative analysis with dry condition indicated that tool life is enhanced up to 100% using cryogenic media. Analysis of cryogenic tool wear map underscored the importance of careful choice of machining parameters in terms of increase in MRR up to 36% and tool life up to 58%. Overall, cryogenic tool wear map presents graphical interpretation of the machinability of Ti–6Al–4V in terms of tool wear.

Tool wear assessment when drilling AISI H13 tool steel multilayered claddings

Laser cladding is a layer-by-layer metal deposition technique often used to deposit high-quality metallic coatings on poorly performant metal alloy surfaces. Nevertheless, to reach the desired surface finish and geometrical tolerances, machining operations after laser cladding may become necessary, whose performances can be significantly affected by the deposition parameters. While the outcomes of milling operations carried out on multi-layered claddings in terms of tool wear and surface integrity have been recently investigated, the same is not available in literature in case of drilling, which is particularly challenging when the drilling operation intersects several layers. In this paper, C45 steel substrates were laser cladded with multiple AISI H13 tool steel layers using different powder size and laser power. The laser cladded samples were characterized on the basis of their microstructural features and micro-hardness. Afterward, drilling trials were conducted on these samples to evaluate the drill bit wear. The effect of the laser cladded-induced microstructure on the tool wear was then assessed at varying deposition parameters. Moreover, the quality of the drilled holes in terms of hole internal surface roughness and hole edge contour was investigated and related to the tool wear. The obtained results showed that, when drilling laser cladded AISI H13 tool steel, the microstructural features induced by the deposition process significantly affect the tool wear and, in turn, the hole quality.

Resource-efficient performance testing of metalworking fluids utilizing single-point milling

ABSTRACT Metalworking fluids have the ability to extend cutting tool life and improve the machinability of materials. There is a need for the development of reliable machining tests which can be used to screen fluids with high confidence to allow for ranking in terms of performance. This study developed a novel methodology utilizing single-point milling to evaluate fluid performance in terms of tool wear and cutting forces across various aerospace alloys. The repeatability of the procedure was assessed and demonstrated by using standard deviation. The study showed alternative cutting fluid compositions could influence tool life performance across all the aerospace material variants. Inconel 718 was shown to be the hardest material to machine followed by Titanium Ti–5Al–5Mo–5V–3Cr and Titanium Ti–6Al–4V. However, with each material, there was a differentiation in fluid performance with up to 11% difference in average tool life between different fluids.

Experimental and 3D-Deform Finite Element Analysis on Tool Wear during Turning of Al-Si-Mg Alloy

Aluminum alloys are becoming increasingly significant in the manufacturing industry due to their light weight and durable properties. Widely applied in aerospace and construction, precision machining is required to ensure the best possible surface quality. The surface quality of a machined component is directly affected by the tool wear incurred during machining. This research investigated the effect of process parameters and machining conditions on tool wear. The critical process parameters selected were cutting speed, feed rate, and depth of cut. Multi-walled carbon nanotube particles were dispersed in a base fluid of mineral oil to create a new lubricant applied during machining. Pure mineral oil was also used as a lubricant to reduce friction. Machining experiments were carried out with the two lubricants, and the tool wear incurred was measured and compared using a Dinolite microscope. All experiments were carried out with high-speed steel (HSS) cutting tools. Taguchi’s L9 orthogonal array was employed as a methodology to design the experiments. A finite-element 3D simulation was also carried out using DEFORM-3D to provide a scientific explanation of the turning process. Results showed a significant reduction in tool wear when machining with multi-walled carbon nanotubes (MWCNTs), with an average reduction of 14.8% compared to mineral oil. The depth of cut was also the most influential process parameter in terms of tool wear.

Machine learning approach in non-intrusive monitoring of tool wear evolution in massive CFRP automatic drilling processes in the aircraft industry

This research presents an analysis of real production data of an automatic drilling industrial system and emphasizes its ability as a process control indicator in terms of tool wear. In particular, the study is framed in Carbon-fiber-reinforced polymer composites (CFRPs) drilling operations carried out at Airbus facilities. The industrial process data were directly collected from the manufacturing plant in Getafe (in the Madrid-Spain region) and come from three different sources: spindle power consumption signals, obtained from the internal instrumentation of the machine, cutting tools wear analysis, and hole quality inspection. The main goal is to use different machining features such as tool accumulated cutting time, together with signal features to feed Machine Learning (ML) algorithms to predict tool wear. To address the inherent variability of complex production systems, it has been proposed a specific methodology that is applicable to control machining operations. The approach includes data collection, data pre-processing, and the application of Linear Regression, k-Nearest Neighbors, and Random Forest ML algorithms. As an outcome to be predicted, a novel qualitative scale of the general condition of the drill is proposed. The predictive models show promising results bearing in mind the quality and quantity of the available data – up to 3500 holes drilled with 8 diamond-coated tungsten carbide tools under different work conditions (number of layers, thickness, and others). The relevance of the benchmarks defined as representative features of the spindle power consumption as well as other machining-related parameters and their relationship with tool wear has been discussed. The Random Forest model gets the best results, being the most interesting variables the accumulated cutting time and the maximum spindle power consumption, and the most irrelevant, the number of parts to be drilled.

Effect of Coconut Oil-Based Cutting Fluid on Cutting Performance During Turning With Minimal Fluid Application

In the present work, an attempt was made to use vegetable oil as a cutting fluid during minimal fluid application to make the process more environmentally friendly. Coconut oil was selected as the vegetable oil in this study considering its availability, physical properties, and lubricating ability. The effect of newly formulated coconut oil-based emulsified cutting fluid on cutting performance during turning of hardened AISI 4340 steel with the minimal fluid application was investigated. It was observed that the coconut oil-based cutting fluid offered better cutting performance in terms of tool wear, surface roughness, cutting force, cutting temperature, and tool chip contact length when compared to mineral oil-based cutting fluid and raw coconut oil. It was also observed that the percentage of concentrate in the cutting fluid was to be maintained as 30% to achieve better cutting performance. The use of coconut oil-based cutting fluid holds promise as an environment friendly alternative for mineral oil-based cutting fluid.

Effect of cryogenic cooling in deep hole drilling process – a stride in the direction of green manufacturing

ABSTRACT In this study research efforts have been made to unveil the ability of Cryogenic machining as a sustainable manufacturing process for deep hole drilling of AISI 1045 and Ti6Al4V. Environmental protection is the most pressing concern for manufacturers today when it comes to adverse health effects caused by cutting fluid and its disposal after usage. For better machining results, choosing the right cutting fluid is important. Investigation on drilling performance is done in terms of tool wear, hole wall temperature (HWT), circularity, surface roughness (Ra) to study the effects of input parameters such as cutting speed, coolant used, feed rate and coolant pressure. The type of coolant employed, cutting speed, feed and coolant pressure have a significant impact in determining the hole quality. Furthermore It was found that the employment of cryogenic coolant (LCo2) was effective on Ti6Al4V in compared with AISI 1045 in many output parameters. HWT of Ti6Al4V was higher compared with AISI 1045 Surface finish was better in Ti6Al4V, tool wear was considerably low while performing deep drilling on Ti6Al4V.

Structure Integrity Analysis on Nickel–Diamond Blade in Dicing of Hard-brittle Ceramic Die

Dicing operation in cutting hard-brittle ceramic die using nickel–diamond blade causes cracked or chipped die, accelerated tool wear and, ultimately, shortage of blade lifetime. This study aims to analyse the structural integrity of dicing blade in terms of tool wear, surface roughness, microstructure and elements during dicing. The measurements of wear blade on the blade are made by confocal microscope, whereas surface and elemental analyses are carried out with EDX SEM. Results show that the volumetric wear rate of blade is 20%, similar to roughness. The microstructure of the blade changes with occurrence of Aluminium owing to abrasive wear mechanism during cutting.

Experimental investigation on tool wear reduction by nano- alumina particles enriched waste coconut oil nano-fluid for machining SAE 1045 shaft

The performance of machining tool can be assessed in terms of tool wear. Increased tool wear has an impact on surface quality. The surface quality of the shaft is a major influence in fatigue load failures. The liquid waste of multiple times used coconut oil are disposed in open channel, which contaminates the soil and ground water and also harm to environment. This study looked into the impact of a Nano fluid containing Nano-alumina particles enriched waste coconut oil on tool wear. The samples in this study were divided into two groups: group I was the control group, and group II was the experimental group, in which the samples were machined (turned) on a heavy-duty lathe using the green machining process. The intervention group's sample was machined using a clean technology approach that included 0.3 percent Nano-alumina particles enriched waste coconut oil based wet machining. To validate the statistical model, the experimented observations were subjected to Taguchi analysis and subsequent examination by ANOVA. Based on the experimental findings, the proposed Nano-alumina particles enriched waste coconut oil based wet machining method was developed.

CFRP drilling process control based on spindle power consumption from real production data in the aircraft industry

Ongoing challenges in advanced manufacturing highlight the need of improved control of the production system, higher production speed, lower tool wear, top quality standards together with reduced material waste to minimize associated costs, time and environmental footprint. The organization of production resources through the integration of data along the value chain using Information Technologies is required to achieve these challenges. Thus, the emergence of the fourth industry revolution brings with it the organization of productive resources through computational intelligence and connectivity. This research seeks to analyze the spindle power consumption in Carbon-fiber-reinforced polymer composites (CFRPs) drilling operations as a process control indicator in terms of tool wear. This signal stands out among others available because it can be obtained in real time, with high quality and through a non-intrusive methodology. In particular, the study is framed in the real production system in factories of Airbus. The industrial process data were directly collected from the manufacturing plant in Getafe (in the Madrid-Spain region) and correspond to more than 3000 holes drilled with diamond-coated tungsten carbide tools. The variability of machining conditions in the aeronautical component drilling process and inherent noise level of signals obtained in industrial environments required the development of a data wrangling methodology to structure and clean the information. As a result, different magnitudes were obtained from spindle power consumption signal related to tool wear with low levels of dependence on drilling conditions. The conclusions of this work are directly applicable to the control of industrial production systems within the framework of Industry 4.0, searching new improvement opportunities through Data analytics and Artificial Intelligence such as tool breakage detection or the optimization of cycle times.

Comparison of machining performance of stainless steel 316L produced by selective laser melting and electron beam melting

Powder bed fusion processes based additively manufactured SS 316L components fall short of surface integrity requirements needed for optimal functional performance. Hence, machining is required to achieve dimensional accuracy and to enhance surface integrity characteristics. This research is focused on comparing the material removal performance of 316L produced by PBF-LB (laser) and PBF-EB (electron beam) in terms of tool wear and surface integrity. The results showed comparable surface topography and residual stress profiles. While the hardness profiles revealed work hardening at the surface where PBF-LB specimens being more susceptible to work hardening. The investigation also revealed differences in the progress of the tool wear when machining specimens produced with either PBF-LB or PBF-EB.

Experimental Study of Tool Wear when Milling Tropical Wood with Various Tool Materials

The paper presents a study on the performance of cutter tip for wood milling process. The tests were performed with the tropical wood samples which were milled in the double sided wood planer, the measured micro-geometrical parameters encompassing the linear wear and tooltip radius. The study primarily contributes to developing a far better understanding of the physical nature of cutting tool wear in response with the growing concern of many researchers. Given this basis, it does not only assist the selection of reasonable cutting tool but also enable the detection of the patterns in the cutting tool wear process. In terms of tool wear and bluntness, there has been a number of researches taking account into the physical nature of cutting tools, - providing basis for selection of cutting tools apart from clarification of the current pattern of tool wear and bluntness. The load applied to the cutter during wood milling is the load that changes marks periodically. When starting to work after tool sharpening and finishing, the first stage changes the microscopic geometry - tool run-in process (rapid initial wear), followed by constant conditions of wear before a rapid wear which leads to failure at last. The objective of this study is to determine the influence of the cutting path to the tooltip radius and linear wear of the cutting edge. The paper employs method of least squares and variance analysis in application of the Minitab software to determine regression equations for relation of the tooltip radius and linear wear to the relative cutting length. The ultimate goal is to predict the life of cutting tool when milling tropical wood.

Effect of annealing on quality enhancement of micro-machining green alumina ceramics by laser ablation

The natural characteristics of sintered ceramics limit the micromachining of functional surface textures in terms of tool wear, processing quality and economic effectiveness. So, the micro-machining of green ceramics before completely sintering is introduced. In this paper, micro-channels are fabricated on the surfaces of green ceramics pretreated by different annealing temperatures. The effect of parametric combination of annealing temperature and laser parameters on the response of processing quality, channel dimension and material removal rate (MRR) are studied by single fact experiments and multi-objective optimization by the response surface method (RSM). The mathematical models of the interaction between different factor combinations are developed based on RSM. Results show that the annealing temperature has significant influence on the aspect ratio under different laser parameters. Continuous channels with few recast layers are always formed at the annealing temperatures of 500–800 °C and a higher annealing temperature always contributes to a larger aspect ratio. Based on the responses of RSM, the optimal parameters of laser ablation and annealing temperature are chosen as laser power of 6 W, scanning speed of 350 mm/s, laser frequency of 40 KHz, and the pretreatment annealing temperature of 750 °C. The experiments validate good agreement of proposed model.

Performance analysis of centrifugal-cast single-point cutting-tools developed from scrapped tools

ABSTRACT Single-point cutting tools were developed adopting a novel technique involving centrifugal casting using scrapped and discarded tools without any compositional adjustments. These tools included single-point cutting tools, drills, milling cutters, etc., and were melted in an induction furnace and cast in a vertical rotating mold. Single-point cutting tools were developed from these cast bars. The cutting ability of these developed tools was compared with that of conventional high-speed steel (HSS) tools that were procured from the market, for cutting of mild steel (A36) workpiece under identical tool geometry and cutting parameters. The cutting ability of the conventional HSS tool and the developed tool was observed to be comparable in terms of tool wear. Further, the surface-finish, force required for cutting and chip-configuration were more or less identical. The performance of the developed tool is comparable with the conventional cast HSS tool within the cutting velocity of 52.77 m/min and yields the most encouraging results, putting these tools at par with those available in the market. Thus, the novel technique adopted is claimed to be a viable method for developing single-point cutting tools without going for stringent methods of compositional adjustments and the costly forging methods for compaction.

Analysis, modeling, and multi-objective optimization of machining Inconel 718 with nano-additives based minimum quantity coolant

In the current study, analysis, modeling, and optimization of machining with nano-additives based minimum quantity lubrication (MQL) during turning Inconel 718 are presented and discussed. Multi-walled carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles were utilized as used nano-additives. The studied design variables include cutting speed, feed rate, and nano-additives percentage (wt. %). Three machining outputs were considered namely: flank wear, surface roughness, and energy consumption. The novelty here focuses on improving the MQL heat capacity by employing two different nano-fluids. The analysis of variance (ANOVA) technique was employed to investigate the influence of the design variables on the studied machining outputs. The results demonstrated that the usage of MQL-nanofluids improved the cutting process performance compared to the classical approach of MQL. It was found that 4 wt. % of added MWCNTs decreased the flank wear by 45.6% compared to the pure MQL. Similarly, it was found that 4 wt. % of added Al2O3 nanoparticles improved the tool wear by 37.2%. Besides, the nanotubes additives showed more improvements than Al2O3 nanoparticles in terms of tool wear, surface quality, and energy consumption. Regarding the modeling stage, artificial neural network (ANN), adaptive neuro-fuzzy inference system (ANFIS), and genetic programming (GP) are employed to model the measured outputs in terms of the studied parameters. These soft computing approaches provide various advantages through their self-learning capabilities, fuzzy principles, and evolutionary computational concept. In addition, a comparison among the developed models has been conducted to select the most accurate approach to present the machining characteristics. Finally, the non-dominated sorting genetic algorithm (NSGA-II) was utilized to optimize the studied cutting processes. Moreover, a comparison between the optimized results from different approaches is presented. The proposed methodology presented in this work can be further implemented in other machining cases to model, analyze as well as optimize the machining performance, especially for the hard-to-cut materials which are commonly used in different industries.

Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP.

Lightweight materials are finding plentiful applications in various engineering sectors due to their high strength-to-weight ratios. Hole-making is an inevitable requirement for their structural applications, which is often marred by thermal damages of the drill causing unacceptable shortening of tool life. Efficient cooling of the tool is a prime requirement for enhancing the process viability. The current work presents a novel technique of cooling only the twist drill between drilling of holes with no effect of the applied cryogenic coolant transferred to the work material. The technique is applied in the drilling of two commonly used high-strength lightweight materials: carbon fibers reinforced polymer (CFRP) and an alloy of titanium (Ti-6Al-4V). The efficacy of the cooling approach is compared with those of conventionally applied continuous cryogenic cooling and no-cooling. The effectiveness is quantified in terms of tool wear, thrust force, hole quality, specific cutting energy, productivity, and consumption of the cryogenic fluid. The experimental work leads to a finding that between-the-holes cryogenic cooling possesses a rich potential in curbing tool wear, reducing thrust force and specific energy consumption, and improving hole quality in drilling of CFRP. Regarding the titanium alloy, it yields a much better surface finish and lesser consumption of specific cutting energy.