Tool Edge Wear Research Articles

Manufacturing Process Optimization and Tool Condition Monitoring in Mechanical Engineering

The optimization of manufacturing and production processes with various computer software is essential these days. Solutions on the market allow us to optimize and improve our manufacturing and production processes; one of the most popular software is called Tecnomatrix, which is described in this paper. Tool condition monitoring is a vital part of the manufacturing process in the industry. It requires continuous measurement of the wear of the cutting tool edges to improve the surface quality of the work piece and maintain productivity. Multiple methods are available for the determination of the actual condition of the cutting tool. Vibration diagnostics and acoustic methods are included in this paper. These methods are simple, it requires only high sensitive sensors, microphones, and data acquisition unit to gather the vibration signal and make signal improvement. Extended Taylor equation is applied for tool edge wear ratio. Labview and Matlab software are applied for the measurement and the digital signal processing. Machine learning method with artificial neural network is for the detection and prediction of the edge wear to estimate the remaining useful lifetime (RUL) of the tool.

Döküm Yöntemi ile Manganlı Çelik Malzemeden Üretilen Abkant Pres Zımba ve Dişi Kalıpların İşlenebilirlik Yönünden İncelenmesi

Punches and dies employed in sheet metal “V” bending have been obtained generally from stock materials, AISI 4140 and EN C45 (Ck 45), in industrial applications through machining. The fact that local and different manufacturing methods have been applied in manufacturing these punches and dies has gained great significance in terms of external dependency and economy. The purpose of this study is to manufacture punches and dies used in “V” bending process from manganese steel via cast method and compare the newly obtained molds with presently used molds in terms of machinability and surface roughness. In this study, the experimental samples from both AISI 4140 and manganese steel were machined at different cutting parameters (cutting speed, feed rate, cutting depth), hence they were compared by analyzing with regard to chip morphology, cutting tool edge wear and surface roughness. At the end of the study, it was concluded that the punches and dies manufactured from manganese steel produced in foundry and widely found are alternatives compared to available AISI 4140 steel molds in terms of machinability.

Microstructure and Corrosion Properties of Wire Arc Additively Manufactured Multi-Trace and Multilayer Stainless Steel 321

Because low thermal conductivity and high viscosity are common characteristics of austenitic steel, it is easy to cause a large amount of heat accumulation in the chip area, resulting in tool edge collapse or wear, and the traditional preparation method is unsuitable for preparing large and complex austenitic steel components. Wire + arc additive manufacturing (WAAM) provides a great application value for austenitic stainless steel because it can solve this problem. The cold metal transfer (CMT)-WAAM system with good control of heat input was used to fabricate the multi-trace and multilayer stainless steel 321 (SS 321) workpiece in this study. The microstructure and corrosion properties of the SS 321 workpiece were observed and compared with those of an SS 321 sheet. The results showed that the microstructure of the SS 321 workpiece from top to bottom was regularly and periodically repeated from the overlapping remelting zone, inter-layer remelting zone, and primary melting zone. There was white austenite matrix and black ferrite, and a small amount of skeleton and worm ferrite was distributed on the white austenite matrix. The average hardness value from the top to the bottom region was approximately uniform, indicating that the workpiece had good consistency. The corrosion properties in 0.5 mol/L H2SO4 solutions were compared between the SS 321 workpiece and the SS 321 sheet. The results showed that the corrosion properties of the top region of the workpiece were better than that of the middle and bottom part, and the corrosion properties of the SS 321 workpiece were better than that of the SS 321 sheet.

Modeling and analysis of surface topography of Ti6Al4V alloy machining by elliptical vibration cutting

The finished surface topography of workpiece is a significant characteristic to evaluate the performance of a processing method. Elliptical vibration cutting (EVC) technique as one of the processing method for sculpturing ultra-precision surfaces has been widely applied in many fields due to the advantages such as reduced cutting forces, better surface roughness, longer tool life, and the machinability of difficult-to-cut materials. For EVC, the machined surface topography is determined by the various cutting parameters. In order to study the influences of different cutting parameters on 3D surface topography of EVC, this paper has established a 3D micro-surface geometrical topography model and carried out series of experiments on Ti6Al4V to verify the effects of relevant cutting parameters on the surface topography. Results show that the surface topography deteriorates with the increment of the feed rate of x- and y-directions, respectively. Furthermore, the wear of tool edge has a significant impact on surface topography.

Study on Alloy Steel TEW 6582 Machined Surface Rougness Under Dry Machining

The purpose of research is to study the surface roughness of machining results obtained to give consideration that the possibility of dry machining can be realized at alloy steel machining of TEW 6582. In the field of surface texture only discuss the machined surface roughness with some testing that is processing and data analysis can be done statistically. The TEW 6582 alloy steel samples were produced from dry machining operations with 9 cutting forms using standard L 9 (34). In this case 3 variations of tool wear are determined by tool edge wear (VB) = 0.1 mm, 0.3 mm and 0.6 mm including also in wet machining. To cut the work piece used CNC machine, optical microscope and surface test . The roughness test was obtained the roughness value with dry machining for optimum cutting conditions ie HPK1.0.1 = 1,467 μm, HPK8,0.3 = 2,133 μm and HPK8,0.6 = 2,8 μm whereas value in wet machining was found with HPB1,0.1 = 1,581 μm, HPB8.0.3 = 2,304 μm and HPB8,0.6 = 2,906 μm. From the above machining results data, HPK8.06 can be determined as the most optimum cutting condition which can be concluded that dry machining gives better machining results roughness through Ravg value and no significant difference is obtained when compared to wet machining after statistically analyzed, so that dry machining is a good chance that can be realized in manufacturing and automotive industries.

Tool edge radius wear and material removal rate performance charts for titanium micro-milling

Micro-machining applications have been extended from electronics to micro-scale medical implants and devices. Micro-milling among the micro-machining processes, has the potential to be the most cost effective and efficient material removal process due to ease of use and accessibility of the tools. Complex challenges are faced due to size effect, vibrations, and other uncontrollable factors coupled with a material like Titanium used in several aerospace and medical applications which is also a representative as difficult to machine material. This study analyzes tool edge wear on micro-end-milling of commercially pure Titanium (ASTM SB 265 GR2) applying design of experiment aided with response surface methodologies to find a proper set of cutting parameters. The results show that it is possible to achieve reduced tool wear while material removal rate is balanced simultaneously. Performance charts are developed to assist in appropriate selection of cutting parameters in Titanium micro-milling.

The influence of technical characteristics of wood milling tools on its wear performance

Influence of technical and chemical characteristics of industrial wood milling tools on its wear was analysed. Four tools of different manufacturers were subjected to the research. Lithuanian oak wood was chosen for the research as a reference material. Behaviour of cutting tools was assessed on the adopted industrial thickness planer SR3-6 with cutting speed of 31 m/s. Wear performance was evaluated on milling the specimens until 3200 m of true cutting length. Summarising achieved results, the following can be stated: chemical composition of tool and heat treatment schedule has great impact on the tool edge wear. The highest wear resistance was reached on testing tools made of CT01M-LA2; tools made of high-alloyed tool steel 8X6HΦT have presented the highest cutting edge radius and edge recession in each type of test as compared with tools made of high-speed tool steels Z80WCV18-04-01/18-0-1 and HS18-0-1, respectively. All these tools are suitable for oak wood processing. The high-alloyed tool steel shows similar wear performance as high-speed tool steels.

Evaluation of tool edge wear during turning with applying the Fractal Dimension

Evaluation of tool edge wear during turning with applying the Fractal Dimension

Evaluation of Tool Edge Wear based on Fractal Dimension

Evaluation of Tool Edge Wear based on Fractal Dimension

Investigation Performance of AlCrN_Based Coated Broaching Tool in Broaching of Gas Turbine Material X12CrMoWVNbN1011

Pull broaching fir-tree slots of gas turbine is one of the most productive precision machining processes when machining simple surfaces or complex contours. Tool edge chipping and wear of uncoated broaching tool become a serious problem in the currently broaching of gas turbine discs. Therefore, tool coating can be used to improve the wear resistance of broaching tool. AlCrN-based coatings have been developed as a high hardness coating for cutters due to excellent resistance to oxidation which is higher than that of conventional coatings. However, few researches had paid attention to investigating AlCrN-based coating tool performance in the broaching process, especially in machining of heat-resisting material of heavy-duty gas turbine discs. In this paper, experiments of broaching heat-resisting material X12CrMoWVNbN1011 were investigated. In order to obtain suitable and ideal broaching tool, the AlCrN coated or uncoated T15 broaching tools were also compared. Cutting force, cutting temperature, and tool wear were measured in the broaching experiments. Results showed that: (1) with a little changed cutting load and tool edge radius, AlCrN-based coating was found to have more significantly influence in improving the tool life as comparing to uncoated tool. The similar wear forms was observed by comparing coated tool and uncoated tool. The conclusions of the study can help to improve heavy-duty gas turbine disc broaching process and broaching tool. (2) Owing to AlCrN coating’s unique combination of heat resistance and hardness, broaching tool could reach higher cutting performance levels. AlCrN coated tool compared with uncoated tool have much better performance in term of cutting strains or cutting temperature.

Effect of Cutting Fluid on Diamond Tool Life under Micro V-Groove Turning of Cobalt-Free Tungsten Carbide

Micro-machining of hard dies and molds for optical parts or precision instruments is required to extend die and mold life. This paper investigates the effect of cutting fluid on diamond tool life under micro V-groove turning of cobalt-free tungsten carbide. Zinc dialkyldithiophosphate fluid (ZnDTP) displayed excellent diamond tool wear resistance in previous experiments. The performance of this cutting fluid is compared to newly developed vegetable oil based cutting fluid with dispersed MoS2 nanotubes. This paper investigates nanopolycrystalline diamond (NPD) tool life with a rake angle of 0° and-30° under continuous micro V-groove turning (i.e. face turning), of cobalt-free tungsten carbide using the developed cutting fluids. Superior diamond tool edge wear resistance is observed when using the dispersed MoS2 nanotubes in vegetable oil and using a NPD tool with a-30° rake angle.

Measuring procedures of cutting edge preparation when hard turning with coated ceramics tool inserts

In this paper, the authors introduce the methodology of combined studies on cutting edge preparation and tool performance testing. Five main fields of research on cutting edge preparation are identified in this study of cutting edge preparation while cutting edge microgeometry consists of data associated with tool edge and rake face. Uncoated and TiN coated mixed oxide ceramics inserts have been tested concerning their microgeometry and wear resistance and there is presented a sequence of measuring to identify cutting edge preparation and properties of coating. Authors propose the sequence which considers cutting edge preparation as a factor controlling performance of cutting edge in hard turning operations. Four steps in the sequence of performance testing include measurements with effects of wear criterion and machining time. Measured results show that combined effects of both preparation and coating reduce considerably friction forces in scratch tests and there is very negligible change of microhardness of uncoated and coated ceramics. Relationships between cutting edge microgeometry and acceptable machined surface roughness which results from the sequence in tool performance testing have been identified. Finally, tool performance indices are based on units which characterize machined surface roughness, tool edge wear and forces when hard turning.

A method of using Hoelder exponents to monitor tool-edge wear in high-speed finish machining

Tool condition monitoring is increasingly important as a widespread application of automated, computer numerically controlled machining in a variety of modern industries. Although a significant amount of research on tool condition monitoring in machining has been conducted during the past few decades, the research is primarily focused on tool flank wear. Less attention is paid to tool-edge wear, which is a critical issue in high-speed finish machining where the feed rate is in the same magnitude as tool edge dimensions, and thus, the tool cutting edge is subjected to extensive mechanical and thermal deformation. The present study fills this important research gap in tool condition monitoring. This paper presents a method of monitoring tool-edge wear in the high-speed finish machining of an aerospace superalloy Inconel 718 by extracting Hoelder exponents from wavelet transform analysis of cutting vibrations. A total of 60 cutting experiments were conducted, covering a range of cutting speed and feed rate conditions. The experimental results show that cutting vibrations increase as tool-edge wear develops. Wavelet transform analysis can be employed to identify single local maxima of the cutting vibration signals. As tool-edge wear develops, the values of Hoelder exponents vary from 0.55 to 0.90. It is suggested that under the cutting conditions tested in the present study, 0.8 can be used as the threshold value of Hoelder exponents to differentiate severe and normal tool-edge wear.

Preliminary evaluation of the applicability of F, V and AEsignals in diagnosis of ADI machining process

Abstract In this study, a preliminary evaluation was made of the applicability of the signals of the cutting forces, vibration and acoustic emission in diagnosis of the hardness and microstructure of ausferritic ductile iron and tool edge wear rate during its machining. Tests were performed on pearlitic-ferritic ductile iron and on three types of ausferritic ductile iron obtained by austempering at 400, 370 and 320°C for 180 minutes. Signals of the cutting forces (F), vibration (V) and acoustic emission (AE) were registered while milling each type of the cast iron with a milling cutter at different degrees of wear. Based on individual signals from all the sensors, numerous measures were determined such as e.g. the average or maximum signal value. It was found that different measures from all the sensors tested depended on the microstructure and hardness of the examined material, and on the tool condition. Knowing hardness of the material and the cutting tool edge condition, it is possible to determine the structure of the material .Simultaneous diagnosis of microstructure, hardness, and the tool condition is probably feasible, but it would require the application of a diagnostic strategy based on the integration of numerous measures, e.g. using neural networks.

Industrial Sawing of Pinus sylvestris L.: Power Consumption

The wood industry continues to strive to reduce production costs and increase productivity to remain competitive. Knowledge of the effect of wood cutting parameters on power consumption could increase energy efficiency, reducing operating costs and increasing profitability. Measuring power consumption also provides information about other variables, such as tool edge wear, occurrence of catastrophic failures, and other parameters that affect the quality of the sawn boards and the momentary efficiency of the breakdown process. In this work, power consumption during sawing of Pinus sylvestris L. using a double arbor circular saw was investigated. Both climb-sawing and counter-sawing were considered. The experiments were carried out under normal production circumstances in two Swedish sawmills. The relationship between cutting parameters and theoretical power consumption was investigated. The experimental power consumption increased by 11 to 35% during an 8-h shift, mainly due to an increase in the tooth radius. Additionally, this study showed that climb-sawing consumed more power than counter-sawing.

A comparative study of high-speed machining of Ti–6Al–4V and Inconel 718 - part I: effect of dynamic tool edge wear on cutting forces

Part II of the present study is a comparative study of high-speed machining of Ti-6Al-4V and Inconel 718, focusing on a comparison between the effects of dynamic tool edge wear on cutting vibrations. This paper describes in detail how cutting vibrations were measured and how vibration signals were processed using a wavelet packet transform technique. A total of 60 high-speed machining experiments were performed, covering a range of cutting speed and feed rate conditions. The experimental results show that tool edge wear has a complex effect on the cutting vibrations. The vibration amplitudes in high-speed machining of Ti-6Al-4V can be higher or lower than those in high-speed machining of Inconel 718, depending on the particular cutting speed and feed rate employed. Analysis of variance reveals that both the cutting speed and the feed rate always play a statistically significant role in affecting the vibration amplitudes in all three directions, i.e., the cutting speed direction, the feed rate direction, and the depth of cut direction. It is also revealed that in high-speed machining of Ti-6Al-4V, four significant wavelet packets (W30, W32, W33, and W36) exist, depending on the particular cutting conditions employed. In high-speed machining of Inconel 718, two significant wavelet packets (W32 and W33) exist, regardless of the cutting conditions employed. The significant wavelet packets identified in part II of the present study can be used as features to detect and monitor tool edge wear in high-speed machining.

A comparative study of high-speed machining of Ti-6Al-4V and Inconel 718—part II: Effect of dynamic tool edge wear on cutting vibrations

A comparative study of high-speed machining of Ti-6Al-4V and Inconel 718—part II: Effect of dynamic tool edge wear on cutting vibrations

Influence of regular and random cutting tool deformation on the cutting force of three-dimensional turning operation

The current work emphasises the impact of the various modes of cutting tool edge wear and failure on the different force components considering the three-dimension orthogonal continuous machining using multi-coated carbide tips. Edge force is usually attributed to the ploughing and rubbing actions on the tool-workpiece interface which, in turn are associated with the extent of the inevitable wear modes: nose, flank, and notch wear. Modelling of the experimental results using linear and non-linear regression analysis is established to qualitatively and quantitatively grasp the functional interrelation among the involved parameters. Results indicated that all force components are, to different extents, affected by all edge wear land modes. However, it is shown that each of the observed edge wear and failure has its own potential on specific force components and on specific cutting pressure.

Tool-Edge Wear and Wavelet Packet Transform Analysis in High-Speed Machining of Inconel 718

Tool-edge wear (i.e., the wear of a tool cutting edge before it is fully worn away) is among significant concerns in high-speed machining because it can result in early tool failure and deteriorated quality of machined parts. Based on extensive experimental results, this paper shows how tool-edge wear is correlated with the cutting forces and vibrations in high-speed turning of Inconel 718. The following research findings are made from the present study: 1) The development of tool-edge wear depends on the initial tool-edge geometry and the cutting conditions employed. 2) The amount of tool-edge wear varies at different measurement points along the tool cutting edge, and increases as the feed rate increases. 3) The effect of tool-edge wear on the cutting forces depends on the initial tool-edge geometry and the cutting conditions employed. 4) The traditional time-domain analysis based on the vibration amplitude is not helpful in explaining and showing the dynamic development of tool-edge wear, and wavelet packet transform helps in identifying the changes in the vibration signals in different frequency bands.

Novel Modeling of Tool Edge Wear

In this article, modeling of the entire curve of the tool edge wear, covering all of its characteristic segments relating to the cutting process (first, without any detectable wear; second, initial wear; third, moderate wear; fourth, accelerated wear), from the beginning to its end, is presented. The excessive tool edge wear ends with the loss of the tool's ability to cut. First, the description of tool life in the entire range of velocity variation is provided. Then the characteristics of the tool edge wear are presented. The need to model other phenomena (material resistance to machining; strenghthening or hardening of the solid; thermal expansion of solid; entropy growth of heated solid, etc.) using a similar method is stressed.