TiN Coated Carbide Tool Research Articles

Effect of Cutting Fluid on Tool Wear in Finished Surface Formation Area of Rounded Nosed Tool When Turning Alloy 304

In this study, the effect of cutting fluid on tool wear in finished surface formation area was investigated when turning alloy 304 with a TiN coated carbide tool under different lubricant conditions and the transition of surface roughness caused by tool wear was investigated. In the case of water-soluble cutting fluid, the higher concentration emulsion caused a smaller wear width VB and larger VB’”. In the case of oily cutting fluid, the lower co-efficient of friction oil caused a smaller wear width VB and larger VB’”. In both cases of water soluble and oily cutting fluid, the cutting fluid of lower coefficient of friction caused a larger wear width VB in milling at the feed rate of around tool edge roundness. This tendency was consistent with the wear width VB” and VB’” in turning. In both cases of water soluble and oily cutting fluid, the cutting fluid of lower coefficient of friction caused a larger cutting force volatility. The feed marks were more irregular in lower coefficient cutting fluids.

Prediction of TiAlN- and TiN-coated carbide tool wear in drilling of bidirectional CFRP laminates using wavelet packets of thrust–torque signatures

Prediction of TiAlN- and TiN-coated carbide tool wear in drilling of bidirectional CFRP laminates using wavelet packets of thrust–torque signatures

Analysis of Cutting Forces and Surface Roughness in Machining Al2219, Unhybrid and Hybrid Metal Matrix Nano Composites using CCD Design of Experiment

Nano Composites (nano MMCs) exhibit outstanding engineering properties like wear resistance, better stiffness, low density, and excellent ratio of strength to weight and so on. Unhybrid and hybrid nano MMC composites were fabricated using liquid metallurgical stir casting technique. Turning of Al2219 through TiN coated carbide tool was carried out to investigate surface roughness and cutting forces, by considering the cutting parameters like feed rate and speed. Response surface methodology (RSM) was used to design the experiments and to analyze the obtained results. The obtained results indicated that the cutting forces and surface roughness increases with increase in feed rate and decreases with increase in cutting speed. RSM displayed model and measured values are truly close to each other, which shows that created model can be effectively used to predict the cutting force and surface roughness on turning of MMCs. The predicted model values and obtained experimental values were close to each other with minimal error of 5 %, so the model is adequate.
 HIGHLIGHTS
 
 Nano Metal Matric Composites reinforced Al2219 with n-B4C & MoS2 particles successfully using stir casting
 Feed rate is the key influencing factor and the cutting speed had slight influence on cutting force, surface roughness and tool wear
 The experimental values obtained and predicted modeled values are within 5 % of each other, then the model is adequate
 
 GRAPHICAL ABSTRACT

Comparison of novel TiN coated and uncoated carbide tool in CNC green machining of AISI H13 to minimize tool wear

To compare the tool wear in green machining (dry turning) of AISI H13 tool steel using novel TiN coated and uncoated carbide tools. The work material chosen for the study is AISI H13 tool steel of dimension 25 mm diameter and 50 mm length. The type of cutting tool selected for the turning operation is novel TiN coated and uncoated carbide tool. The designation of the cutting tool used is CNMG120408. Three input parameters are considered, cutting speed (m/min), feed rate (mm/rev), depth of cut (mmm) and each varied at three different levels for conducting L9 experimental study. Two groups of experimental study are selected (novel TiN coated and uncoated) with 27 samples per group. The sample size is calculated with 80 % of total pretest G power. In total, 54 samples were taken for the study of tool wear. The testing set-up of tool wear in carl zeies microscope. The experimental study was conducted in the green machining (dry turning) environment. The Average of tool wear (microns) The novel TiN coated carbide tool is lesser tool wear and uncoated carbide tool is higher tool wear are recommended. All the results obtained were analysed for its significance by SPSS software and the graphs were plotted and the level of significance was found to be 0.048 (p < 0.05). The samples machined with novel TiN coated carbide tool gives good results compared with uncoated carbide tool to minimize Tool wear.

Correlating surface roughness with cutting temperature in face milling of Al-6061using CRITIC approach

Keeping in mind the harmful effects of cutting on human health and environment, dry machining is employed vastly in machining of easy to cut materials. However, dry machining involves relatively high heat generation at cutting zone which leads to deterioration of finish quality of machined surface. The magnitude of this deteriorationis further high in case of softer material like aluminum alloy. In current study, an attempt is made to find the correlation of the surface roughness with cutting temperature while machining the aluminium alloy. Face milling experimentation was performed on aluminium alloy (Al-6061) using TiN coated carbide tools inserts under near dry cutting conditions employing Minimum Quantity Lubrication (MQL). CRITIC approach is exploited to determine the correlation between the surface roughness and cutting temperature. The results of CRITIC with Pearson correlation coefficient value of 0.9167, indicates the strong correlation between surface roughness and cutting temperature. The optimum parameter setting for the surface roughness is discovered as 160 ml/hr coolant flow rate, 50 mm spraying distance, and 45° nozzle elevation angle.

Comparison of novel TiN coated and uncoated carbide tool in CNC dry turning of EN31 to analyse chip profile

The objective of the present study is to compare novel TiN coated and uncoated carbide tool during CNC turning of EN31 alloy steel to analyse chip profile. Materials and Methods: Two groups of cutting tool novel TiN coated and uncoated, are used for machining of EN31 in dry turning operation. The three input parameters selected for present experimental study are cutting speed (m/min), feed (mm/rev) and depth of cut (mm). Each parameter is varied at 3 different levels with the conduct of L9 experimental studies. The chip profile of EN31 is measured at 25 mm machined length. Two groups of experimental study are selected (novel TiN coated and uncoated) with 27 samples per group and chip thickness is measured on three chips taken from one experimental run and the average is utilized for chip thickness calculation. On the whole 54 samples are collected and measured for 2 groups. The sample size is calculated with 80 % of total pretest G power. Results: The chip thickness was found to be 16 % high when the machining process was done with coated tools when compared to uncoated tools. The value of the thickness of the chip(microns) was found to be low when a lower feed rate is given and value of thickness was high when we gave a higher feed rate. All the results obtained were analysed for its significance by SPSS software and the graphs were plotted and the level of significance was found to be 0.049 (p < 0.05). Conclusion: Within the limitations of this study, it was found that machining of selected material, EN31, by using novel TiN coated carbide tool results in maximum chip formation when compared with an uncoated carbide tool during wet turning process.

Experimental Investigation and ANFIS-Based Modelling During Machining of EN31 Alloy Steel.

This research presents the parametric effect of machining control variables while turning EN31 alloy steel with a Chemical Vapor deposited (CVD) Ti(C,N) + Al2O3 + TiN coated carbide tool insert. Three machining parameters with four levels considered in this research are feed, revolutions per minute (RPM), and depth of cut (ap). The influences of those three factors on material removal rate (MRR), surface roughness (Ra), and cutting force (Fc) were of specific interest in this research. The results showed that turning control variables has a substantial influence on the process responses. Furthermore, the paper demonstrates an adaptive neuro fuzzy inference system (ANFIS) model to predict the process response at various parametric combinations. It was observed that the ANFIS model used for prediction was accurate in predicting the process response at varying parametric combinations. The proposed model presents correlation coefficients of 0.99, 0.98, and 0.964 for MRR, Ra, and Fc, respectively.

Planetary motion cross bar friction test for application in machining process

This paper describes a new method to evaluate the friction coefficient at the tool-work interface in machining process where high stress and temperature are caused. In order to examine the feasibility of the proposed method, the present report introduces the method and the results obtained only at room temperature. Ti6Al4V, SUS304, AISI1045, FCD 700, FCD 450 and FC300 were used as work materials, while TiN coated carbide tool, TiAlN coated carbide tool and P15 were used as tool materials. The proposed method provided the friction coefficients of different coatings against different work materials, and demonstrated the variability of friction coefficient and the anisotropy of surface roughness.

Effect of Process Parameters on Cutting Forces and Surface Roughness in Machining of DSS 2205 Using Taguchi’s Approach

In the present study an attempt has been made to investigate the effect of process parameters on surface roughness and cutting forces generation in machining of Duplex Stainless Steel (DSS 2205) grade material with TiN coated carbide tool. Taguchi technique is used for optimizing the process parameters. L27orthogonal array was used to conduct the experimental trials. Cutting forces recorded using piezo-electric based mill tool dynamometer and surface roughness measured using surface roughness measuring instrument. The obtained results indicated that the cutting force increases with increase in feed rate and depth of cut whereas cutting forces decreases with increase in cutting speed. Surface roughness decreases with increase in cutting speed and low feed rate. Scanning Electroscope Microscopic (SEM) images indicates the feed marks, undeformed material and patches on the machined surface. The formation of material side flow and burrs on the feed marks ridges observed at higher cutting speed, low feed rate and depth of cut. It is mainly due to the material behavior like elastic-plastic deformation of the surface layer. The material side flow causes the considerable deterioration of surface quality of the DSS 2205 steel.

Performance evaluation of Titanium nitride coated tool in turning of mild steel

The growth in demand for bio-gradable materials is opened as a venue for using vegetable oils, coconut oils etc., as alternate to the conventional coolants for machining operations. At present in manufacturing industries the demand for surface quality is increasing rapidly along with dimensional accuracy and geometric tolerances. The present study is influence of cutting parameters on the surface roughness during the turning of mild steel with TiN coated carbide tool using groundnut oil and soluble oil as coolants. The results showed vegetable gave closer surface finish compares with soluble oil. Cutting parameters has been optimized with Taguchi technique. In this paper, the main objective is to optimize the cutting parameters and reduce surface roughness analogous to increase the tool life by apply the coating on the carbide inserts. The cost of the coating is more, but economically efficient than changing the tools frequently. The plots were generated and analysed to find the relationship between them which are confirmed by performing a comparison study between the predicted results and theoretical results.

Wear Characteristics of Coated Carbide Tools in the Face Milling of Ductile Cast Iron

This study reports an experimental investigation about the wear behavior of TiN and TiCN coated carbide tools during the face milling of pearlitic and ferritic ductile cast iron. Pearlitic ductile cast iron caused the highest cutting forces and flank wear in both TiN and TiCN coated tools. Due to its protective effect, the TiCN coated carbide tool outperformed the TiN coated carbide tool regarding flank wear. The main issue when face milling ferritic ductile cast iron with TiN coated tools was notching wear. The principal reason for notch wear was pointed as adhesive wear caused for the high tendency of ferrite to adhere on the tool. The results demonstrated that the TiCN coating did not showed notching wear when face milling ferritic ductile cast iron, therefore a good choice of coating material can prevent notching wear.

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

BackgroundNow-a-days, newer hardened steel materials are coming rapidly into the market due to its wide applications in various fields of engineering. So the machinability investigation of these steel materials is one of the prime concern for practicing engineers, prior to actual machining.MethodsThe present study addresses surface roughness, flank wear and chip morphology during dry hard turning of AISI 4340 steel (49 HRC) using CVD (TiN/TiCN/Al2O3/TiN) multilayer coated carbide tool. Three factors (cutting speed, feed and depth of cut) and three-level factorial experiment designs with Taguchi’s L9 Orthogonal array (OA) and statistical analysis of variance (ANOVA) were performed to investigate the consequent effect of these cutting parameters on the tool and workpiece in terms of flank wear and surface roughness. For better understanding of the cutting process, surface topography of machined workpieces, wear mechanisms of worn coated carbide tool and chip morphology of generated chips were observed by scanning electron microscope (SEM). Consequently, multiple regression analysis was adopted to develop mathematical model for each response, along with various diagnostic tests were performed to check the validity and efficacy of the proposed model. Finally, to justify the economical feasibility of coated carbide tool in hard turning application, a cost analysis was performed based on Gilbert’s approach by evaluating the tool life under optimized cutting condition (suggested by response optimization technique).ResultsThe results shows that surface roughness and flank wear are statistically significant influenced by feed and cutting speed. In fact, increase in cutting speed resulted in better surface finish as well as increase in flank wear. Tool wear describes the gradual failure of cutting tool, caused grooves by abrasion due to rubbing effect of flank land with hard particles in the machined surface and high cutting temperature. Chip morphology confirms the formation of saw-tooth type of chip with severity of chip serration due to cyclic crack propagation caused by plastic deformation. The total machining cost per part is found to be $0.13 (i.e. in Indian rupees Rs. 8.21) for machining of hardened AISI 4340 steel with coated carbide tool.ConclusionsFrom the study, the effectiveness and potential of multilayer TiN/TiCN/Al2O3/TiN coated carbide tool for hard turning process during dry cutting condition possesses high yielding and cost-effective benefit to substitute the traditional cylindrical grinding operation. Apart, it also contributes reasonable option to costlier CBN and ceramic tools.

Optimization of Machining Parameters for Surface Roughness in End Milling of Magnesium AM60 Alloy

Objective: The present work is aimed to find an optimum combination of cutting parameters to achieve low surface roughness in end milling of magnesium AM60 with TiN coated carbide tool under dry conditions. Methods: Design of Experiments (DOE) with Response Surface Methodology (RSM) using Box-Behnken design and the regression equations are used to find the optimal combinations of cutting parameters to achieve low surface roughness. The developed RSM model was experienced through Analysis of Variance (ANOVA). An ANOVA analysis was performed to indicate the control of three machining parameters on the surface roughness. Findings: The cutting parameters assessed were spindle speed, depth of cut and feed rate have the greatest effect on the success of the milling operation. Confirmation experiments with the optimum combinations of cutting parameters were carried out in order to explain the efficiency of the response surface design concepts. From ANOVA results, the feed rate was found to be most significant factor affects surface roughness of milled surface. Feed rate, depth of cut and spindle speed affects the surface roughness by 76.18%, 2.94% and 1.99% respectively. It can be fulfilled that RSM method is effective and efficient method to optimize milling parameters for low surface roughness. Applications: Magnesium (Mg) is now emerging as a popular metal for replacing Aluminum (Al) and finding applications in automobile and aerospace industries where fine finishing of the machined component is ultimate requirements to achieve a product quality.

Chip Formation in the Machining of Al-Si/10% AlN Metal Matrix Composite by using a TiN-coated Carbide Tool

This paper presents a study on chip formation in the milling process of Al-Si/10% AlN Metal Matrix Composite (MMC). It focuses on the effect of cutting parameters on the formation of the chip. Al-Si/10% AlN MMC reinforced with 10% AlN particle is a new-generation material that is suitable for manufacturing automotive and aerospace components. Several advantageous characteristics of this material include low density, light weight, high strength, high hardness and high stiffness. The milling process was carried out at dry cutting conditions by using TiN-coated carbide tool insert, which was developed by Standards and Industrial Research Institute of Malaysia (SIRIM). The machining parameters were as follows: a constant cutting speed of 230 m/min, feed rates of 0.4, 0.6 and 0.8 mm/tooth and cutting depths of 0.3, 0.4 and 0.5 mm. The analysis of the chip formation was performed using a video microscope (Sometech, SV-35). The chips were formed because of the shear between the work pieces and the cutting chips during dry milling of Al-Si/10% AlN MMC. These chips were small, short and discontinuous with outer face cracks.

Influence of cutting fluid conditions and cutting parameters on surface roughness and tool wear in turning process using Taguchi method

In this experimental work, the effect of various cutting fluid levels and cutting parameters on surface roughness and tool wear was studied. Taguchi orthogonal array was employed to minimize the number of experiments. The experiments were carried out on mild steel bar using a TiCN+Al2O3+TiN coated carbide tool insert in the CNC turning process. The effect of feed rate was found to be the dominant factor contributing 34.3% to surface roughness of the work-piece. The flow rate of the cutting fluid also showed a significant contribution (33.1%). However, cutting speed and depth of cut showed little contribution to surface roughness. On the other hand, cutting speed (43.1%) and depth of cut (35.8%) were the dominant factors influencing tool wear. However, application of cutting fluid (13.7%) showed a considerable contribution, while the feed rate gave the least contribution to tool wear. The optimum cutting conditions for desired surface roughness and tool wear were at a high level of cutting speed, medium level of depth of cut, low level of feed rate and low-flow high-velocity (LFHV) cutting fluid flow from the selected levels.

Online optimization of a finish turning process: strategy and experimental validation

The present work carries out online optimization of a finish turning process using a fuzzy set-based optimization strategy. The strategy does not require a priori machining models. The proposed optimization strategy is expected to be efficient for the problem with a large number of design variables. It also acknowledges the presence of statistical variation in the process. The experimental demonstration of the proposed strategy is presented for finish turning of cold- rolled steel with TiN-coated carbide tool. The basis of tool life is maximum allowable surface roughness. The strategy of reusing the failed tool by modified cutting conditions is also implemented on the shop floor.

The Effects of TiAlN and TiN Coating during End Milling of INCONEL 718

Inconel 718 is a registered trademark of Special Metals Corporation that refers to a family of austenitic nickel-chromium-based super alloys. This material usually being used or operate in high temperature and extreme condition like aerospace industry, turbocharger rotors and seals. This research presents an experimental study of the cutting force variation, surface roughness, tool life and tool wear in end milling Inconel 718. The experimental results showed that flank wear was the predominant failure mode affecting tool life for TiAlN and TiN coated carbide tool. TiAlN is the better coated tool than TiN because it produce better surface finish and resultant force. Feed rate is one of the parameter that effecting results in this experiment. The higher feed rate will shorten the life of the tool. Although for the cutting condition, the situation is quite different where the proper cutting speed will maintain the tool life and tool wear for cutting tool. The overall study shows that TiAlN coated carbide tool with cutting speed 100 m/min, depth of cut 0.5 mm and feed rate 0.1 mm/tooth is the optimum parameter in this experiment.

Numerical characterisation of the friction coefficient at the tool-chip-workpiece interface during friction tests of AISI 1045

The characterisation of frictional phenomena at the tool–chip–workpiece interface in metal cutting remains a challenge. This paper aims at identifying a workpiece surface temperature and an equivalent plastic strain at this interface during the dry cutting of an AISI 1045 with TiN–coated carbide tools. A 3D arbitrary Lagrangian Eulerian (ALE) numerical model simulating the frictional test has been developed to extract local parameters around the spherical pin, such as the plastic strain and the workpiece surface temperature, from experimental macroscopic measurements. A large range of sliding velocities (5–300/min) has been investigated. It has been shown that plastic strain and workpiece surface temperature are mainly dependent on sliding velocity. Two friction regimes have been identified. These numerical results provide a better understanding of the tribological phenomena along the tool–chip–workpiece interfaces in dry machining of an AISI 1045 steel with a TiN–coated carbide tool.

Effect of Graphite Particles in Drilling of Hybrid Aluminum Matrix Composite

In aluminum matrix composites, presence of hard particles inside the matrix which causes tool wear, poor surface finish and high cutting forces while machining. This paper discusses the influence of graphite particles and cutting parameters on drilling characteristics of hybrid aluminum matrix composites (AMCs)—Al6063/6%Al2O3p and Al6063/6%Al2O3p/1%Grp. The composites are fabricated using stir casting method. Experiments were conducted with TiN coated carbide tools and commercial carbide tools at various cutting speeds and feeds. Design of experiment of full factorial design is employed to analyze the drilling characteristics of these composites. Burr height and surface roughness of the drilled hole was investigated with special attention paid to the effects of graphite particles. The chips formed when machining graphitic composites are more discontinuous which led to better surface finish than non graphitic composite.

PERFORMANCE EVALUATION OF TIN COATED CARBIDE INSERT FOR OPTIMUM SURFACE ROUGHNESS IN TURNING OF AISI 1045 STEEL

In manufacturing industry, beside the dimensional a nd geometric tolerance of a component, surface qual ity is most commonly specified requirements. Surface roughness plays an important role in the performance of the component. This paper presents a study of the influence of the cutting parameters on the sroughness during the turning of AISI1045 ste el with TiN coated carbide tool. The design of experiments based on the Taguchi tech nique. The objective was to optimization of the mac hining parameters as cutting speed, feed rate and depth of cut for surface rough ness. Main effect plots are generated and analyzed to find out the relationship between them. Afterwords a confirmation test were pto make a comparison between the predicted results and the theoretical results.