Tungsten Carbide Tool Research Articles

Flank wear characteristics of WC-Co tools when turning Alloy 718 with high-pressure coolant supply

In the present study, the tool wear mechanisms of uncoated cemented tungsten carbide (WC-Co) tools during machining Alloy 718 with high-pressure coolant supply are investigated. Worn flank faces are analyzed by scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX). With increasing spiral cutting length, larger areas on the tool surface are subjected to erosion of Co-binder by the coolant jet impact. Moreover, the amount and morphology of workpiece-precipitates adhered on worn flank surfaces are influenced significantly by the extent of flank wear land (due to increasing spiral cutting length). The reasons for the obtained results are addressed with respect to the underlying mechanisms. Possible implications for the tool wear behavior are discussed.

Thermal Stability of Cathodic Arc Vapour Deposited TiAlN/AlCrN and AlCrN/TiAlN Coatings on Tungsten Carbide Tool

TiAlN/AlCrN and AlCrN/TiAlN bilayer coatings were deposited on tungsten carbide cutting inserts using the plasma enhanced physical vapour deposition process. Their thermal stability was varied by annealing the specimens at different temperatures and time durations. The thermal stability was evaluated from hardness measurement, oxygen absorption and X-ray diffraction (XRD) patterns. TiAlN/AlCrN coating initially shows an increase in hardness, but it decreases when the annealing temperature is increased. A high hardness of 46 GPa is measured in the TiAlN/AlCrN coating annealed at 600 °C for 08 h. But, AlCrN/TiAlN coating displays a decrease in hardness after annealing at 600 °C, and the hardness increases to 47 GPa on increasing the annealing temperature further (1000 °C for 6 h). From weight measurements, it is clear that the TiAlN/AlCrN bilayer coating results in weight reduction initially, but it increases with a further increase in the annealing temperature. In contrast, in the AlCrN/TiAlN coating, the weight increases monotonically, but gradually, with increasing temperature of annealing. The XRD results are discussed with reference to the different oxide phases formed in the two bilayer coatings during annealing.

Effect of tool rotational speed on mechanical properties and microstructure of friction stir welding joints within Ti–6Al–4V alloy sheets

Friction stir welding of Ti–6Al–4V alloy sheets was successfully performed with a tungsten carbide (WC) tool, and the effect of the tool rotational speed on the microstructure and mechanical properties of the joints was evaluated. The microstructure was investigated using field emission scanning electron microscopy, electron backscattered diffraction and X-ray diffraction measurements. Tensile, Charpy impact and Vickers hardness tests were performed to evaluate the joints’ mechanical properties. The process peak temperature of each welding condition was measured at the bottom of a specimen. Regardless of the welding conditions, the alpha (α) and alpha prime (α′) phases were detected in the stir zone, whereas the base metal was composed of alpha (α) and beta (β) phases. The tensile strength and hardness of the stir zone increased as the tool rotational speed increased. The impact absorption energy was found to be equal to that of the base metal. Moreover, a phase transformation from the β to the α′ phases occurred in the stir zone during friction stir welding and the evolution of the microstructure in the stir zone significantly affected the mechanical properties of the joints.

Mechanical and Tribological Properties of CrWN Nanostructured Hard Films

This work determines optimal settings for the deposition parameters of CrWN hardened, nanocomposite films grown on tungsten carbide tools and glass substrates with direct current (DC) reactive magnetron co-sputtering. Using metallic Cr and W targets, argon was the plasma gas and nitrogen was the reactive gas. An orthogonal array, the signal-to-noise ratio and analysis of variance are together used to analyze the effect of the deposition parameters. The Taguchi method was used to design a robust experiment. Then deposition parameters of the CrWN hard films, including Cr DC power (Watts), W DC power (Watts), N2/(Ar+N2) flow-rate ratios (%) and deposition time (min) were optimized with reference to structure of the films, dry turning tests of AISI 316 stainless steel (50 mm diameter) and wear tests of CrWN films. This study uses a grey-based Taguchi method to determine the parameters of the coating process for CrWN hard films by considering multiple performance characteristics. In the confirmation runs, according to grey relational analysis, improvements were noted of 6.17% in the surface roughness, 26.27% in the flank wear, and 6% in the coefficient of friction. The wear resistance of CrWN films can be evaluated by considering the other mechanical properties, including elastic recovery, hardness and Young’s modulus, which are obtained from the nanoindentation testing.

The effect of plastic deformation rate on the wear performance of hardfaced coatings

The objective of this study aimed to investigate the effect of plastic deformation rate and heat treatment routes on the wear performance of surfaced coatings obtained using submerged arc welding (SAW) and flux supplemented by additions of alloying powder. Powder of cemented tungsten carbide and high-speed tool steel has been selected as additives to the composition of shielding flux AMS1. Graphite powder was used as addition in two test batches in order to compensate carbon content, which burns out during welding. Results of spectrum analysis have revealed high concentration of alloying elements (Co 0.91–1.573%, W 2.5–9.5%, Mn 1.67–2.39%), which ensured low wear of tested coatings. Tempering at different temperatures showed formation of retained austenite; this fact was confirmed after X-ray diffraction analysis. Different extent of plastic deformation was accomplished to all test batches on the purpose of evaluation of influence on the wear performance of coatings. Wear results showed proportional dependence of rate of deformation and weight loss values. Addition of graphite helped to reach the lowest wear of coatings obtained using the flux alloyed with cemented tungsten carbide and high-speed tool steel (weight loss 0.12 and 0.148 g, respectively).

СHANGE OF THE MICROSTRUCTURE OF ENAMEL AND DENTIN UNDER THE INFLUENCE OF THE ROTARY TOOL IN THE TREATMENT OF CARIES (IN VITRO STUDY)

At the present stage of development of the basic tool for cutting of necrotic tissues and forming, a cavity in the treatment of dental caries remains a rotary tool. Since the main dental restoration technique is adhesive technology, the quality of the enamel and dentin adhesive surfaces plays a decisive role in the future as a treatment. In vitro, using scanning electron microscopy was studied impact complex of hard teeth tissues preparation components (type cutting tool drive, feed rate, etc.) on the microstructure of adhesive enamel and dentin surfaces. Modeled and rendered the most frequently committed errors by doctors at preparing dental hard tissues. Diamond tool in combination with the turbine drive has the most adverse effect on the microstructure of dentin. Inadequate selection of tungsten carbide tools leads to significant destruction of enamel prisms, which in turn is responsible for violations of the adhesion of filling materials and recurrent caries. Just complete an adequate combination of the above components of hard teeth tissues preparation provides the necessary condition of the adhesive surfaces and high-grade quality of the composite adhesion.

Performance of lightweight coated oxide ceramic composites for industrial high speed wood cutting tools: A step closer to market

Abstract The introduction of lightweight cutting tips in industrial wood machining could lead to machining at much higher speeds and thus greatly increase efficiency. One possible way to achieve this is through lightweight ceramic composites. An Al 2 O 3 ceramic matrix was selected and reinforced with particles resulting in a density of approximately one quarter of the currently used heavy tungsten carbide tools (density of >15 g/cm 3 ). Furthermore, a coating was applied to the ceramic cutting tools in order to increase the stability of the cutting edge. A combination of reduced coefficient of friction, frictional forces and a resulting decrease in temperature can lead to a reduction in chipping at the cutting tip. Chipping has always been the major drawback of ceramic cutting tools for industrial wood cutting. A ceramic composite containing 25 vol% of submicron and nano sized SiC particles shows good mechanical properties with HV 2 =21.5 GPa and K Ic =4.5 MPa m 1/2 . This composition performed very well in industrial cutting trials on laminated beech. The cutting performance was increased further by use of an industrially available coating on the tools. The quality of the cut wood surface has always been difficult to characterize when comparing cutting tool materials and is often performed qualitatively by experienced carpenters by touch. The surface quality of the machined laminated beech was for the first time quantitatively characterized using Gelsight 2.5D tactile sensing.

Microstructure, microhardness and tensile properties of FSWed DP 800 steel

Purpose: Dual phase (DP) steels are widely used in the automotive industry due to their properties of a high balance of strength and formability. However, it is known that conventional welding of high strength steel leads to some undesirable results such as hardness decrease in the heat affected zone. Friction stir welding (FSW) is a new solid state joining method, which is used to join these steels due to its advantage of low heat input. The aim of this study is to evaluate the microstructural change and mechanical properties of friction stir welded DP800 steel. Design/methodology/approach: DP 800 steels with 1.5 mm thickness were subjected to friction stir welding, by using a tungsten carbide (WC) tool. The tool was tilted 2°, and downforce of the tool was kept constant at 6 kN. During processing, the tool rotation and traverse speed were fixed at 1600 rpm and 170 mm∙min-1, respectively. Findings: The friction stir welded region comprises martensite, bainite, refined ferrite. The average microhardness of stir zone has increased from 260 HV0.2 to about 450 HV0.2. The tensile sample shows a decrease in the ultimate tensile strength (σUTS) about 3%, from 827 MPa to 806 MPa for the joint. The yield strength (YS) of the joint is about 566 MPa and the value is near that of DP800. Research limitations/implications: The tungsten carbide tool used for the friction stir welding has suffered deterioration in the pin profile after 1 meter welding operation. It may be advisable to drill a pre-hole in the specimens for a longer tool life. Practical implications: Tool wear for industrial applications will be a major problem. Therefore, the use of tools with high wear resistance such as polycrystalline cubic boron nitride may be recommended. Originality/value: Works on friction stir welding of dual phase steels are limited and they mostly focus on spot welding. Also, this study systematically investigates the microstructure and mechanical properties of dual-phase 800 steels after the friction stir welding.

Finite Element Method Based Modeling for Tool Wear Prediction in Orthogonal Cutting Process

Finite element method (FEM) plays vital role in simulation of many complex problems in fields such as machining, automotive, aerospace, etc. Tool wear is one of the machining problems that is essential in research due to its importance and its effect on product quality and cost. This paper shows the utilization of finite element method in modeling of two dimensional orthogonal cutting process to predict tool wear of uncoated tungsten carbide tool using Abaqus/CAE program. The simulation methodology included the implementation of Johnson-Cook (J-C) model to define the material behavior. Also, the adaptive meshing technique (ALE) is used in simulation the cutting process to combine the advantages of Lagrangian technique that is commonly used in solid mechanics analysis and Eulerian techniques that is commonly used in fluid mechanics analysis. The objective is to predict tool wear location on tool face by using finite element method and compare the results with the experimental work.

Identification and modeling of cutting forces in ball-end milling based on two different finite element models with Arbitrary Lagrangian Eulerian technique

This paper presents two different finite element (FE) models with Arbitrary Lagrangian Eulerian (ALE) technique to evaluate the effectiveness of FE modeling for estimating the cutting forces in ball-end milling. The milling forces are modeled using a unified mechanics of the cutting approach, which is based on the shear stress, friction coefficient and chip thickness ratio provided through the orthogonal cutting process. Two-dimensional (2D) FE models of the orthogonal cutting are designed for estimating the milling forces using this approach, and explicit dynamic thermo-mechanical analyses are performed to determine the orthogonal cutting data from a set of cutting and material parameters. The oblique transformation approach is used to carry the orthogonal cutting data to the milling cutter geometry. Simulations are numerically and analytically carried out for machining of 20NiCrMo5 material with a tungsten carbide tool and the estimated forces are compared to measured ones. The estimation of milling forces is accurately achieved by the unified mechanics of cutting approach with orthogonal cutting data based on the ALE technique using Eulerian-Lagrangian boundaries. Good agreements between the estimated and measured outcomes reveal an obvious knowledge of an efficient and accurate FE model for determining the ball-end milling forces.

PREDICTION AND INVESTIGATION OF SURFACE ROUGHNESS WHILE TURNING SG IRON WITH CUBIC BORON NITRIDE (CBN) AND TUNGSTEN CARBIDE INSERTS

This work compares the effect of cubic boron nitride (CBN) and multilayer (TiCN+Al2O3+TiN) coated tungsten carbide (WC) tools during the turning of spheroidal graphite (SG) nodular iron. Nodular irons have more ductility which is required in mechanical components that demand high fatigue resistance like crankshafts, cam shafts, bearing caps and clutch housings. The impact of various process parameters like the depth of cut, cutting speed and feed on the surface roughness (Ra) of SG iron is studied and optimized using the response surface model. The chip morphology is also discussed for evaluation of the quality of the turned surface. The experimental outcomes reveal that the WC tool offers a high surface finish at the optimal combination of the cutting speed at 102 meter/minute, feed at 0.051 millimeter/revolution and depth of cut at 0.5 millimeter and that, for the CBN insert, at 245 meter/minute of cutting speed, 0.051 millimeter/revolution of feed and 0.75 millimeter of depth of cut.

Chips Morphology Analysis under Graphene Oxide Suspension with Tungsten Carbide Tool in Drilling Ti-6Al-4V

Recently, titanium alloys have been widely used in industry owing to their excellent physical and mechanical properties. However, the severe cutting conditions such as abrasion, adhesion and high temperature accelerate the rate of chip formation and strongly affect the quality of machined surface. This paper investigates that the effect of the conventional coolant (CC) and graphene oxide suspended (GO) on the drilling process of titanium alloy Ti-6Al-4V using tungsten carbide tools. Here are two main chip formation could be found that zigzag chips and spiral chips. Through the analysis of chip morphology, it was found that under graphene oxide suspended fluid. It can be found that using conventional coolant would form the zigzag chips, while it formed spiral chips when graphene oxide suspended fluid applied. In addition, by analysing the chip free surfaces, the chip lamella stuck and chip flaw happened when conventional fluid used. While the back surfaces could be found that less chip stuck and crack occurred when graphene oxide suspended coolant applied. Finally, chip thickness were investigated that thinner chip thickness was found when graphene oxide suspended fluid used.

Online Monitoring of Metal cutting of Inconel600 with Al2O3 coated carbide tools

The present research work focuses on experimental investigation of the effect of machining parameters on temperature distribution on work piece, cutting forces and surface roughness of Inconel 600 using Tungsten carbide tool with Al2O3 coating and without coating. The measurement of interface zone temperatures on work piece was performed using infrared thermal camera. The cutting, feed, thrust forces were measured using Kristler dynamometer. The surface roughness was measured by using Taylor Hobson surface roughness tester. The experimental work was initially carried with Full Factorial Design to evaluate the effect of machining parameters on the temperature distribution on workpiece,cutting forces and surface roughness with uncoated tools.Using this data optimized machining parameters were computed using ANOVA.In view of comparison of performance with Al2O3 coated tool bits, L9 orthogonal array of DOE using Al2O3 coated tools was done. The reduction in cutting forces, interface temperatures and surface roughness was more with the use of coated carbide tool when compared with uncoated tool.

Experimental investigation of surface roughness in high-speed micro end milling of near alpha titanium alloy

Super alloys are widely used in many applications such as aerospace, automotive, biomedical, marine, mining and oil industries. In high-speed micro end milling (HSMEM) of super alloys, the proper selection of cutting tool is necessary to achieve good surface quality without burrs. Surface roughness characterisation is crucial on the work materials to achieve the desired production rate in limited time and at low cost. In this research work, surface roughness characterisation was investigated in order to opt for the better possible tool for machining Near Alpha Titanium Alloy Grade-12 under feasible conditions. The influence of machining parameters i.e. cutting speed, feed and depth of cut on surface roughness was investigated in the present work. Experiments were conducted under dry cutting conditions using Uncoated, PVD Coated TiAlN & AlTiN tungsten carbide tools. It was observed that machining with uncoated tungsten carbide tools generates less surface roughness on near alpha titanium alloy.

Optimization of Machining Parameters for Improving Energy Efficiency using Integrated Response Surface Methodology and Genetic Algorithm Approach

Machine tools consume enormous amount of energy during machining, build-up to machining, post machining and idling condition to drive motors and auxiliary equipments in the manufacturing system. Reduction of energy consumption during the machining phase is extremely important to improve the environmental performance over the entire life cycle. This paper presents a predictive and optimization model based on integrated response surface methodology and genetic algorithm approach to predict the energy consumption and the corresponding machining parameters during the turning of AISI 1045 steel with a tungsten carbide tool. Experiments using Taguchi design are performed to develop the predictive model. The developed predictive model is used to formulate the objective function for genetic algorithm. The confirmation experiments are performed to validate the developed model and the results are found within 4% error. The statistical significance of the developed model has been tested by the analysis of variance test. This research will be beneficial for a number of manufacturing industries for selection of machine tools on the basis of energy consumption. The reduction of peak load through optimization will results in lowering the energy consumption of the machine tools during non-cutting time.

Experimental Investigation on Turning of Turbine Blade Material AISI 410 under Minimum Quantity Cutting Fluid

Turbine blade materials are super alloys and they are under go high temperature during machining process between tool and work piece it causes failure of cutting tool and effect the work piece surface roughness. The cutting fluids are used for reducing the effect of temperature in the cutting zone in this context the present paper investigates the turning of turbine blade material AISI 410 with Tungsten carbide tool under the dry, wet and menthol mixed with water cutting conditions. In the dry lubrication the air passes in the cutting zone at room temperature 25°C. In the wet lubrication only waterflows on cutting zone with different temperature say 10°C, 15°C and 25°C. In the third condition small quantity of crystalline menthol powder added to water and used as a cutting fluid. The cutting fluid pressure, velocity maintained constant in all three cutting conditions. A comparison between dry, wet and minimum quantity of menthol is investigated. Finally the results shown that menthol mixed with water act as a better coolant and it concluded that sustainability of machining process has been increased by replacing conventional cutting fluids with developed eco-friendly cutting fluids.

Evaluation of the delamination factor for drilling of compact laminate composite material with tungsten carbide tools

Evaluation of the delamination factor for drilling of compact laminate composite material with tungsten carbide tools

Multi-performance optimization of micro-EDM drilling process of Inconel 600 alloy

In this study, the grey relational analysis was applied to find a unique optimal parameter setting for micro-electrical discharge machining (micro-EDM) drilling process of Inconel 600 alloy. For this, the five effective process parameters such as voltage, capacitance, EDM feedrate, pulse-on time and pulse-off time are varied and microholes were drilled using tungsten carbide tool. The material removal rate, taper angle, overcut and diameteral variance at entry and exit of a microhole were the measured performance characteristics. Analysis of variance (ANOVA) was performed to understand the effects, contributions and significance of the process parameters. Capacitance is observed the most influencing parameter followed by the voltage and EDM feedrate controls the taper angle. From the confirmatory test results, it is revealed that optimized parameter setting gives better machining performance characteristics. With this approach, the form accuracy and surface quality of microholes can be improved effectively.

Wheel lift-off in creep-feed grinding: thermal damage, power surge, chip thickness and optimisation

An investigation is made into the phenomenon of early lift-off in creep-feed grinding, where the wheel lifts away from the workpiece before reaching the end of cut. In single-pass operations, early lift-off can result in thermal damage. In multi-pass operations, there is a surge in material-removal rate just before lift-off, which can result in thermal damage and excess wheel wear. This study examines the current inadequate methods of dealing with lift-off. It then develops a geometric and kinematic model for analysing the lift-off phenomenon. It finally proposes a thermal-model-based optimisation method for achieving a constant maximum surface temperature, resulting in shorter cycle times and less risk of thermal damage. The power-surge model is validated experimentally in diamond grinding of tungsten-carbide rotary tools.

Experimental Evaluation of Direct Laser Assisted Turning through a Sapphire Tool

Laser assisted machining (LAM) techniques have been investigated to improve the efficiency and quality of machining operations by thermally softening hard to cut materials. Traditionally, the techniques were applied in such a way that the heating zone was in front of the cutting tool, softening materials prior to chip formation. In order to reduce energy consumption and prevent unwanted phase changes in the materials, we propose a direct laser assisted machining technique where a laser beam is applied through a transparent sapphire tool, directly affecting the tool-workpiece contact surface. The sapphire tool has a high hardness compared to conventional tungsten carbide tools, while its transparency allows for the direct application of the laser through the tool. In this study, we investigated the effects of applying a direct laser assisted machining technique, and we observed changes in cutting behaviors including cutting forces, surface finish, and adhesion. Aluminum and bulk metallic glass workpiece materials were examined to investigate how crystalline and amorphous materials behave under direct laser assisted machining techniques. Experimental results showed that the proposed technique reduced forces and improved surface finish.