Tool Nomenclature Research Articles

Investigation of Machining Parameters for Turning Process

Manufacturing industries mainly concentrates on how to minimize the cost of the products. The process planers have to prepare the process plan of the product based on the availability of the recourses. All the information is available in the plan including inspection and delivery date of the product. Based on the recommendation of the manufacturing and inspection methods, components are produced at affordable cost. Most of the research work concentrated on selection of machining parameters using optimization techniques and also prove that the machining time / cost were minimized for the particular components / operations. In this work, tool nomenclature is to be considered for the investigation for selection of machining parameters. Work presents an experimental investigation of the influence of the three most important machining parameters of depth of cut, feed rate and spindle speed on surface roughness during turning of aluminium alloy. In this study, the design of experiment which is a powerful tool for experimental design is used to optimize the machining parameters for effective machining of the work piece. L9 orthogonal array experimental design method as well as analysis of variance (ANOVA) is used to analyse the influence of machining parameters on MRR & Machining Time. Two different grade of aluminium alloy i.e. AL 6063 & AL 6068 were machined with input parameters of depth of cut and speed. The output parameters are MRR and machining time. Based on the results empirical equations are formed and optimized results are validation .The optimal results are recommended to manufacturing industries.

APPLICATION OF MULTI CRITERIA DECISION MAKING OF SETTING INPUT PROCESS PARAMETERS FOR DRILLED PRODUCT QUALITY OF Al Si7 Cu4

Apparently, the drilling geometry and treatment influence the drill operation and its performance. Factually, the performance given by the drill bit is powerfully associative with efficiency, hence with economical fabrication. As a further matter, typical performance indicator, that is deviation from diameter, Cylindricity, tool wear, surface roughness is have been changed by drilling geometry. This fact that stress needed for novelty in drill design with further performance indicator optimization for quality of hole. In that prospect, here new drilling geometries were used. Various Drilling trials stayed directed utilizing the L9 orthogonal array. Various treatment processes like heat treatment, cryogenic or untreated (just as received) were carried out. Various tool nomenclature involving changing of helix angle were considered. The investigation performed on AlSi7Cu4 alloy with standard cutting tool, utilized all by trial made under dry cutting conditions. Later, drills were used to obtain hole on AlSi7Cu4, and their performance were examined and optimized to suggest optimum constraints of best attention. To estimate the performance of the drills, the drill quality of the hole stayed studied in terms of deviation of diameter, Cylindricity, and tool wear, surface roughness by the parameter optimization and the percentage of contribution were carried out by VIKOR methodology. As a result, geometry was developed by consideration of these negativities, and was found to show up superiority in performance when compared to other geometries in terms of quality of hole.

Influence of radial rake angle and cutting conditions on friction during end milling of Nimonic 263

In machining processes, the friction and frictional stress formation along the interface between the chip and the tool rake face give rise to energy consumption, tool wear, and failure. This study aims to investigate the influence of tool nomenclature (radial rake angle) and cutting conditions (spindle speed and table feed velocity) on the impediment of friction and frictional stress in the perspective of equivalent pressure coefficients during end milling process, and additionally, the comparative study has been made. The experimental outcome clearly indicates that the machining parameter and tool nomenclature have significant effects on frictional stress impediment under pure sliding condition. Among these, tool nomenclature has higher and significant beneficial impact on the obstruction of frictional stress formation, and it is also stated that the cutting force and friction decreases, when the radial rake angle of cutter decreases when the helix angle and the positive axial rake angle is constant.

Effect of severe plastic deformation through machining on the microstructure and corrosion behavior of end milled nimonic 263 alloy

In this study, the influence of Severe Plastic Deformation (SPD) through end milling (machining) with varying tool nomenclatures such as Radial Rake Angle (RRA) of end mill cutter and cutting conditions such as table feed velocity on the roughening to faceting phenomena and Grain Boundary Characteristic Distribution (GBCD) along with its dependency on corrosion behavior of end milled nimonic 263 alloy have been reported. The experimental result confirms that the decrement in tool nomenclature such as RRA of cutter has a greater and significant effect on the facet morphologies as well as corrosion behavior of SPD processed samples followed by a cutting condition and confirmed that the SPD process through machining has greater impact over the corrosion resistance of machined work surface compared to the as-received sample.

Experimental Investigations on the Effect of Severe Plastic Deformation Through End Milling on X-Ray Peak Broadening and Microcrystalline Characteristics of Nimonic 263

In the present work, the quantitative contributions of severe plastic deformation (SPD) through machining on the microcrystalline features and fatigue life of SPD processed Nimonic 263 have been investigated. X-ray diffraction line profile analysis (XRDLPA) has been executed to compute the likely makeover of microcrystalline characteristics such as crystallite size, lattice strain and dislocation density using full width at half maximum of diffraction peak, and additionally, the influences of these characteristics on fatigue life of the SPD processed samples have been analyzed. To deconvolute these characteristics, Williamson–Hall methods such as uniform deformation model, uniform energy density deformation models (UEDM) and uniform stress deformation model (USDM) are employed. The XRDLPA of machined samples has confirmed a significant broadening of peaks, due to lattice distortions and grain refinement during machining, and a plot of root mean square (RMS) of lattice strain (erms) versus lattice strain (e) has resulted in no inconsistency related to the lattice plane and crystallographic direction. Further, other related physical parameters such as uniform stress, Young’s modulus and energy density are also evaluated using UEDM and USDM models. As a result of the study, it is clear that the substantial influence comes from tool nomenclature over machining parameters.

Comparative studies of variation in end mill radial rake angle and cutting conditions on cutting force and surface integrity during machining of nimonic 263

Tool nomenclature has a profound effect on the machining of alloys and the cutting force during machining. In this study, the effect of changes in radial rake angle of end mill cutter (+7°,0°, −7°) and machining parameters such as spindle rotational velocity (v) and table feed velocity ( f ) on cutting force and surface roughness were presented using regression analysis and a comparison has been made with the measured surface roughness and cutting force data. Additionally, to confirm the goodness of fit, Analysis of variance (ANOVA) has been undertaken and found that the developed empirical model is significant. The experimental outcome clearly indicates that the radial rake angle of end mill cutter is the most significant parameter, which reflect higher efficiency during machining followed by table feed velocity. Spindle rotational velocity is found to be a least significant parameter. Furthermore, the analysis of chip morphology confirmed the behavioral changes while machining due to the presence of variation in tool nomenclature and machining condition.

An experimental investigation on the effect of radial rake angle and machining conditions during end milling on wear resistance and residual stress of nimonic 263 alloy

The tribological and mechanical protection offered to end milled nimonic 263 alloy by the Severe Plastic Deformation (SPD) through machining has been undertaken in the current work. The dry milling of Nimonic 263 alloy has been carried out with a TiAlN coated tungsten carbide tool using vertical machining center. In this study, the surfaces of end milled nimonic 263 are analyzed through x-ray Diffraction Line Profile Analysis (XRDLPA) to evaluate the possible transformation on residual stress using measured interplanar distance between two parallel atomic planes. The quantifiable contributions of machining conditions such as tool nomenclature and machining parameters on the provoked beneficial residual stress on the top surface of the machined samples are evaluated. The SPD processed samples through machining have exposed a significant increment in residual stress which leads to increase the hardness and wear resistance compared to the nascent sample. Further, it reveals that the tool nomenclature has a great extent on the wear resistance followed by machining parameter. Additionally, this study has been carried out to obtain significant machining parameter and tool nomenclature which reflects higher wear resistance of Nimonic 263.

Effect of variation in behavioural changes during end milling on Nimonic 263 elastic constants

Machining of aerospace alloy such as nimonic 263 is a challenging task due to its intrinsic characteristics. In this study, the effect of Severe Plastic Deformation (SPD) through machining on its inherent characteristics such as young modulus, bulk modulus, etc have been investigated. The machining has been done using vertical machining center with the help of tungsten carbide tool with PVD coated TiAlN. X-ray diffraction line profile analysis is used to determine the changes in crystallite size and dislocation density on deformed samples through machining. Furthermore, ultrasonic wave method through pulse echo technique has confirmed the changes in elastic constants and lattice stability of machined samples, due to Severe Plastic Deformation (SPD) on machined sample. Quantitative contributions of machining parameter, tool nomenclature effect on surface modification, elastic constants and intrinsic characteristics of machined sample are evaluated and found that the machining have exposed a significant enhancement in elastic constants and hardness compared to the nascent sample. Further, it reveals that the tool nomenclature has a higher influence on the enhancement in material properties followed by machining parameter. The results portray that the significant contribution comes from dislocation density and disorder followed by crystallite size.

Experimental investigation of surface morphological changes during end milling of nimonic 263

Machining of Nickel - cobalt alloy is a challenging task and it is responsible for a significant contribution on intrinsic properties such as wear resistance, etc. Performing machining processes with better surface and metrological properties will reduce the total cost consumption in aerospace sector. In this study, the surfaces of end milled nimonic 263 have been analysed through optical 3D profilometer to investigate the changes in the surface characteristics such as surface roughness, surface texture and surface morphology, etc. The machining (SPD) has been done using vertical machining center with the help of tungsten carbide tool coated with TiAlN. Quantifiable contributions of tool nomenclature and the machining parameters on characteristics of machined sample are evaluated. It is found that, the behavioural changes during end milling have great impact and influence on surface characteristics. Additionally, it has been observed that there is an existence of correlation between the parameters of surface roughness such as Ssk, Sku, etc and the quantitative contributions of tool nomenclature and machining parameters. Furthermore, the results illustrate that the tool nomenclature has a great extent on surface roughness followed by table feed and spindle rotational velocity and it has been confirmed through ANOVA and scanning electron microscope.

Modeling of Face Milling Operation for Assessing Cutter Trajectory and Cutting Forces

Simulation is essential to help designing a cutting tool or selection of a milling cutter. This paper presents an approach of detailed modeling of face milling operation. Theoretical cutter trajectory has been considered. Cutting force components and cutting power consumption of face milling for linear path of cutter have also been modeled. An algorithm for this purpose has been evolved in this work. Validation of angle relationship previously investigated in machining has been shown. Detail plots of dynamic rake angle, instantaneous feed, cutting force components, cutting power with respect to time are established theoretically. Some relevant data have been assumed like material property, cutting tool nomenclature, etc., for showing graphical presentations. Simulation results obtained in this work have been compared with the experimental data available in a published literature. Simulated results from the proposed model using Oxley angle relationship are found to be quite close to the experimental results already reported.

Mechanistic force modeling of single point cutting tool in terms of grinding angles

The cutting tool angles have conventionally been presented using projective geometry in terms of the projections of cutting edges on respective planes, which makes the visualization of geometry difficult, particularly for complex tools. Modeling a cutting tool using the actual grinding angles can simplify the geometric definition of the tools and provide a comprehensive and simple definition of tools for downstream applications. The paper presents the 3D definition of the faces of a single point cutting tool (SPCT) in terms of 3D rotational grinding angles and maps the new tool nomenclature with the ASA, ORS and NRS nomenclatures. A mechanistic model is subsequently proposed to predict the forces in terms of the grinding angles, chip thickness and velocity using second degree polynomial function, unlike the conventionally used logarithmic ones. The model has been calibrated for HSS tool and Mild Steel workpiece combination for end turning of a tubular workpiece based on the regression analysis of a central composite design of the experiments. The results have been discussed and the model has been validated for a new set of experimental data. The model shows a good correlation to the observed results.

Geometric modeling of single point cutting tool surfaces

In this paper we have established a new three-dimensional standard to specify single point cutting tool geometry. The paper models a single point cutting tool in terms of biparametric surface patches. Six new angles, called grinding angles, are proposed to define the orientation of these surface patches. Forward and inverse mappings among grinding angles (α i , β i , γ i ), conventional tool nomenclature (γ y, γ x, α y, α x , ..... ), and setting or swivel angles for grinding (θ A , θ B , θ C ) are established. The benefits of the new paradigm include ease of finite element based engineering analysis, simulation, and programming of the CNC tool cutter and grinder for tool sharpening. The proposed methodology is illustrated with a few numerical examples.

Reference systems for cutting tool geometry and their transformation matrices

SUMMARY A generalized specification and reference system for three-dimensional cutting tool geometry is developed based on established standards of tool nomenclature. The proposed system of tool specification, designed to meet the requirements of optimal metal cutting, as well as grinding and inspection of the cutting tool geometry, consists of three basic parts : (a) Tool Grinding Reference System, (b) Tool Working Reference System, and (c) Machine Tool Reference System.Using matrix methods, the general transformations required to relate the tool geometry to any of the three proposed reference systems are developed. The analysis is illustrated with a numerical example.

A System of Specification of Lathe Tool Nomenclature

From the mechanics of turning operation, a system of specification of lathe tool nomenclature is derived. The system also satisfies the criteria of ease of grinding and ease of inspection.

Some Practical Aspects of Cutting Tool Nomenclature Arising from Recent Research

In recent years a considerable volume of research has been carried out to improve the techniques employed in the most widely used metal machining processes. An essential preliminary to all these experiments in turning, milling, drilling, tapping, etc., was accurate control of tool shapes. This necessitated the development of adequate tool-measuring equipment and a comprehensive nomenclature. The nomenclature has resulted from an analysis of tool geometry, and an examination of applicable tool grinding methods and inspection equipment. The nomenclature has been extended to take account of factors which were proved by research to be of considerable practical significance in the ultimate tool performance. Nomenclatures for the most commonly used types of tool are presented as a basis for discussion together with typical examples of tool geometry, tool grinding methods, and tool inspection equipment which should be taken into account when developing improved nomenclatures. Reference is also made to some of the British, European, and American standards, which have an important place in these discussions. Some of the problems involved in the workshop application of cutting tool nomenclatures are also considered. Recently, significant advances have been made in tool nomenclature as a result of the increasing co-operation between manufacturers and users of tools, but the nomenclature used for development work in research stations, colleges, universities, and industrial research laboratories, needs to be more comprehensive and precise than that at present used in general engineering practice.