Tungsten Carbide Cutting Tool Inserts Research Articles

Influence of Cryogenic Treatment on Tungsten Carbide Cutting Tool Inserts in Improving Resistance to Flank Wear in Machining C-45 Steel

Influence of Cryogenic Treatment on Tungsten Carbide Cutting Tool Inserts in Improving Resistance to Flank Wear in Machining C-45 Steel

The effect of transition-metal seeding powder on deposition and growth of diamond synthesized by hot filament chemical vapor deposition processes on cemented carbide substrates and its characterization

Hot Filament Chemical Vapor Deposition is a well-established method to synthesize diamond thin films on a non-diamond substrate. Here, we have deposited microcrystalline diamond on tungsten carbide cutting tool insert by using conventional Hot Filament Chemical Vapor Deposition technique. The substrates were ultrasonically seeded with Carbon, Diamond, Iridium, Molybdenum, Palladium, Platinum, Tantalum, Tungsten and Chromium natural powders and thereafter were deposited with the same deposition parameters to observe the effects of different seeding powders on the diamond coating. The coated tools were characterized by X-ray Diffraction and the quality of diamond crystals was assessed by using micro Raman spectroscopy. The surface morphology was studied by utilizing Scanning Electron Microscope. The discrete spherical diamond crystals were formed with carbon powder seeding while very dense along with uniform coatings were deposited on the diamond powder seeded substrate. Larger diamond crystals with good density were observed on the palladium seeded substrate. The micro Raman spectroscopy showed mixed results of sp3 and sp2 bonding. But the palladium seeding showed clear sp3 bonding due to the formation of crystals with bigger size. The Vickers microhardness value for the substrate with diamond seeding was found to be much higher than other coated tools.

Performance evaluation of cryo-treated tungsten carbide inserts in machining PH stainless steel

Abstract This article details the performance evaluation of deep cryogenically treated tungsten carbide cutting tool inserts in machining of Precipitation Hardened Stainless Steel (PHSS). Machinability study of PHSS has been performed in terms of tangential cutting force, surface roughness and flank wear using cryo-treated tungsten carbide inserts. The experimental analysis disclosed that at higher cutting speeds the inserts that had undergone cryogenic treatment observed less cutting forces, greater tool life and wear resistance. Unlike cutting force, surface finish also witnessed as better while machining with cryo-treated inserts.

Machining With Cryogenically Treated Carbide Cutting Tool Inserts

With the development newer materials for aerospace, marine, automobile industries it became inevitable to develop new cutting tool materials with competitive performanceand productivity. In this regard Sintered Carbide tools were developed to meet the modern machining requirements. But they failed miserably to due to rapid wear in machining high strength and temperatureresistance alloy. This necessitated the need for bringing out innovative changes in machining process and controlling the various parameters associated. One such promising technique is subjecting the tool inserts to Cryogenic Treatment to alter the mechanical properties like hardness, strength and Wear resistance. Cryogenic treatment refers to process of exposing the metals to temperatures below -180°C and soaking for a predetermined period and then allowing ascending back to room temperature at slow cooling rates. In the present work, uncoated Tungsten Carbide cutting tool inserts of geometry SNMG 120408-MR4 have been used. The inserts were cryogenically treated at -183°C and were subjected to tempering in electric muffle furnace by placing on refractory brick at temperatures 250 °C and 300 °C for 120 minutes both followed by air cooling and furnace cooling. The samples showed appreciable improvement in hardness and microstructure study revealed that carbide phase distribution was fairly uniform with binder phase segregating slightly in few cases. Under all cutting velocities, Cryo-treated and tempered inserts showed the highest tool life and wear resistance. It was found that tempering has a significant influence on the phases present in WC+Co inserts and subsequently influences their machining performance. Cryogenic treatment significantly improved the mechanical properties of both the tested tool materials.

Influence of Cutting Fluid Flow Rate and Cutting Parameters on the Surface Roughness and Flank Wear of TiAlN Coated Tool In Turning AISI 1015 Steel Using Taguchi Method

AbstractThis paper presents the influence of cutting parameters (Depth of cut, feed rate, spindle speed and cutting fluid flow rate) on the surface roughness and flank wear of physical vapor deposition (PVD) Cathodic arc evaporation coated TiAlN tungsten carbide cutting tool insert during CNC turning of AISI 1015 mild steel. Analysis of Variance has been applied to determine the critical influence of cutting parameters. Taguchi orthogonal test design has been employed to optimize the process parameters affecting surface roughness and tool wear. Depth of cut was found to be the most dominant factor contributing to high surface roughness (67.5%) of the inserts. However, cutting speed, feed rate and flow rate of cutting fluid showed minimal contribution to surface roughness. On the other hand, cutting speed (45.6%) and flow rate of cutting fluid (23%) were the dominant factors influencing tool wear. The optimum cutting conditions for desired surface roughness constitutes the following parameters such as medium cutting speed, low feed rate, low depth of cut and high cutting fluid flow rate. Minimal tool wear was achieved for the following process parameters such as low cutting speed, low feed rate, medium depth of cut and high cutting fluid flow rate.

Comparative Evaluation of Performances of TiAlN-, AlCrN- and AlCrN/TiAlN-Coated Carbide Cutting Tools and Uncoated Carbide Cutting Tools on Turning EN24 Alloy Steel

In the present work, the performances of TiAlN-, AlCrN- and AlCrN/TiAlN-coated and uncoated tungsten carbide cutting tool inserts are evaluated from the turning studies conducted on EN24 alloy steel workpiece. The output parameters such as cutting forces, surface roughness and tool wear for TiAlN-, AlCrN- and AlCrN/TiAlN-coated carbide cutting tools are compared with uncoated carbide cutting tools (K10). The design of experiment based on Taguchi’s approach is used to obtain the best turning parameters, namely cutting speed ([Formula: see text]), feed rate ([Formula: see text]) and depth of cut ([Formula: see text]), in order to have a better surface finish and minimum tool flank wear. An orthogonal array (L[Formula: see text] was used to conduct the experiments. The results show that the AlCrN/TiAlN-coated cutting tool provided a much better surface finish and minimum tool flank wear. The minimum tool flank wear and minimum surface roughness were obtained using AlCrN/TiAlN-coated tools, when [Formula: see text][Formula: see text]m/min, [Formula: see text][Formula: see text]mm/rev and [Formula: see text][Formula: see text]mm.

Multi-Objective Optimization using Grey Relational Taguchi Analysis in Machining

Multi-objective optimization is becoming important day by day due to increase in complexity of the processes and expectations of more reliable solutions. In view of the complexity of the process, controlling the machining parameters without compromising on the response parameters is a tedious process. In the recent approach, researchers have used many combinations of available techniques to solve multi performance characteristic problems depending upon the situation and accuracy desired in the results, to make the results more reliable. In this paper, the authors have pronounced and used a combination of grey relational and Taguchi based analysis to optimize a multi-objective metal cutting process to yield maximum performance of cutting tools in turning. Main cutting force, power consumption, tool wear and material removal rate were evaluated used L18 orthogonal array considering cutting speed, feed rate and depth of cut, using cryogenically treated and untreated tungsten carbide cutting tool inserts.

Optimizing Feed Force in Turning Process Using Taguchi’s Parameter Design Approach

The objective of the paper is to obtain an optimal setting of turning process parameters (cutting speed, depth of cut and feed rate) resulting in an optimal value of the feed force when machining En19 steel with tungsten carbide cutting tool inserts. The effects of the selected turning process parameters on feed force and the subsequent optimal settings of the parameters have been accomplished using Taguchi’s parameter design approach. It was indicated by the results that the selected turning process parameters significantly affect the selected machining characteristic. The percent contributions of parameters as quantified in the S/N ANOVA envisage that the relative power of cutting speed (72.09 %) in controlling variation and mean feed force is significantly higher than that of the depth of cut (22.30 %) and feed rate (05.31 %). The predicted optimum feed force is 98.067 N. The results have been validated by the confirmation experiments.

Predictive Modeling of Turning Operations Using Response Surface Methodology

This paper focuses on the development of a predictive model using the measured forces acting on the cutting tool during turning operation of AISI 1045 Steel using a Tungsten Carbide cutting tool insert. On the basis of the experimental results, second order mathematical model is developed in terms of machining parameters by using the Response Surface Methodology (RSM). The results are analyzed statistically and graphically. It has been observed that the predicted values using RSM also follow the same trend as given by the measured values.

TURNING STUDIES OF DEEP CRYOGENIC TREATED P-40 TUNGSTEN CARBIDE CUTTING TOOL INSERTS – TECHNICAL COMMUNICATION

In the present work, coated tungsten carbide tool inserts of ISO P-40 grade were subjected to deep cryogenic treatment at −176°C. Turning studies were conducted on AISI 1040 workpieces using both untreated and deep cryogenic treated tungsten carbide cutting tool inserts. The turning performance was evaluated in terms of flank wear of the cutting tool inserts, main cutting force and surface finish of the machined workpieces. The flank wear of deep cryogenic treated carbide tools was observed to be lower than that of untreated carbide tools in machining of AISI 1040 steel. The cutting force during machining of AISI 1040 steel was lower with the deep cryogenic treated carbide tools when compared with the untreated carbide tools. The surface finish produced on machined AISI 1040 steel workpieces was superior with the deep cryogenic treated carbide tools as compared to the untreated carbide tools.

Machining performance of low temperature treated P-30 tungsten carbide cutting tool inserts

Machining studies were conducted on C45 workpiece using both untreated and low temperature treated tungsten carbide cutting tool inserts. The machinability of the C45 steel workpiece is evaluated in terms of flank wear of the cutting tool inserts, main cutting force and surface finish of the machined workpieces. The flank wear of low temperature treated carbide tools is lower than that of untreated carbide tools on machining of C45 steel. The cutting forces during machining of C45 steel is lower with the low temperature treated carbide tools when compared with the untreated carbide tools. The surface finish produced on machining the C45 steel workpiece is better with the low temperature treated carbide tools when compared with the untreated carbide tools.

Performance studies of deep cryogenic treated tungsten carbide cutting tool inserts on machining steel

Machining studies were conducted on a carbon steel workpiece using both untreated and deep cryogenic treated P-20 tungsten carbide cutting tool inserts. The flank wear of deep cryogenic treated carbide tools is lower than that of untreated carbide tools on machining of C45 steel. The cutting force during machining of C45 steel is lower with the deep cryogenic treated carbide tools when compared with the untreated carbide tools. The surface finish produced on machining the C45 steel workpiece is better with the deep cryogenic treated carbide tools when compared with the untreated carbide tools.

Machinability of C45 steel with deep cryogenic treated tungsten carbide cutting tool inserts

Abstract In the present investigation, coated tungsten carbide ISO P-30 turning tool inserts were subjected to deep cryogenic treatment (−176 °C). Machining studies were conducted on C45 workpiece using both untreated and deep cryogenic treated tungsten carbide cutting tool inserts. The machinability of the C45 steel workpiece is evaluated in terms of flank wear of the cutting tool inserts, main cutting force and surface finish of the machined workpieces. The flank wear of deep cryogenic treated carbide tools is lower than that of untreated carbide tools on machining of C45 steel. The cutting force during machining of C45 steel is lower with the deep cryogenic treated carbide tools when compared with the untreated carbide tools. The surface finish produced on machining the C45 steel workpiece is better with the deep cryogenic treated carbide tools than when compared with the untreated carbide tools.

Machinability of bronze–alumina composite with tungsten carbide cutting tool insert

Abstract Bronze–alumina metal matrix composites have been attracting the interest of researchers in recent years, as they have many advantageous characteristics. The mechanical properties of the bronze–alumina composite are improved by the addition of alumina in the matrix. In this present work, bronze was reinforced with 10 wt% alumina particles. The bronze–alumina composite was prepared by stir-casting method. Preheated alumina particles were introduced into the vortex of the molten alloy created by a rotating impeller. Machining studies were conducted on bronze and bronze–alumina composite using tungsten carbide cutting tool insert. The flank wear of the carbide tools on machining bronze–alumina composite is higher than on machining bronze because of the abrasive characteristics of alumina. The cutting force during machining of bronze is lower when compared to that on machining bronze–alumina composite. The bronze exhibited slightly better surface finish than bronze–alumina composite.

Performance evaluation of cryogenically treated tungsten carbide cutting tool inserts

This paper presents an overview of the effects of various subzero thermal treatments on the tool life and wear characteristics of cobalt-bonded tungsten carbide cutting tool inserts. The inserts were subjected to six different conditions of treatment, namely (a) as-received, (b) quenching treatment, (c) cryogenic treatment, (d) cryogenic treatment followed by tempering, (e) cold treatment and (f) cold treatment followed by tempering. It was found that the inserts that had undergone the latter four conditions of treatment exhibited significantly greater tool life and wear resistance at higher cutting speeds, as well as an overall increased resistance to chipping. Microstructural analysis was used to explain the observed phenomena.

Composition, structure, and wear resistance of TiAlOC coatings deposited by chemical vapor deposition

The deposition of TiwAlxOyCz (TiAlOC) coatings onto cemented tungsten carbide cutting tool inserts by chemical vapor deposition is reported. The TiAlOC coatings are shown to exist in three phase regions: a single‐phase TiAlOC solid solution, a mixture of TiAlOC solid solution and α‐Al2O3, and a mixture of TiC and α‐Al2O3. The wear resistance of coatings from each phase region versus standard commercial coatings is reported.