Search results for: cutting tool replacement

Authors: Tadahiro Wada, Shinichi Enoki, Hiroyuki Hanyu

Abstract:

In this study, WC-Ni-based cemented carbides having different nickel contents were used as the substrate for cutting tool materials. Hardened steel was turned by a (Ti,W,Si)N-coated WC-Ni-based cemented carbide tool, and the tool wear was experimentally investigated. The following results were obtained: (1) In the (Ti,W,Si)N-coated WC-Ni-based cemented carbide, the hardness of the coating film was not much different from the content of the binding material, Ni, and the adhesion strength increased with a decrease in Ni content. (2) There is little difference between the wear progress of the (Ti,W,Si)N-coated WC-7%Ni-based cemented carbide tool and that of the (Ti,W,Si)N-coated WC-6%Co-based cemented carbide tool. (3) The wear progress of the (Ti,W,Si)N-coated WC-Ni-based cemented carbide became slower with a decrease in Ni content.

From the above, it is has become clear that WC-Ni-based cemented carbide can be used as a substrate for cutting tool materials.

Keywords: Rare metals, turning, WC-Ni-based cemented carbide, (Ti, W, Si)N coating film, hardened steel.

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Authors: Alexandru Epureanu, Virgil Teodor

Abstract:

One of the main research directions in CAD/CAM machining area is the reducing of machining time. The feedrate scheduling is one of the advanced techniques that allows keeping constant the uncut chip area and as sequel to keep constant the main cutting force. They are two main ways for feedrate optimization. The first consists in the cutting force monitoring, which presumes to use complex equipment for the force measurement and after this, to set the feedrate regarding the cutting force variation. The second way is to optimize the feedrate by keeping constant the material removal rate regarding the cutting conditions. In this paper there is proposed a new approach using an extended database that replaces the system model. The feedrate scheduling is determined based on the identification of the reconfigurable machine tool, and the feed value determination regarding the uncut chip section area, the contact length between tool and blank and also regarding the geometrical roughness. The first stage consists in the blank and tool monitoring for the determination of actual profiles. The next stage is the determination of programmed tool path that allows obtaining the piece target profile. The graphic representation environment models the tool and blank regions and, after this, the tool model is positioned regarding the blank model according to the programmed tool path. For each of these positions the geometrical roughness value, the uncut chip area and the contact length between tool and blank are calculated. Each of these parameters are compared with the admissible values and according to the result the feed value is established. We can consider that this approach has the following advantages: in case of complex cutting processes the prediction of cutting force is possible; there is considered the real cutting profile which has deviations from the theoretical profile; the blank-tool contact length limitation is possible; it is possible to correct the programmed tool path so that the target profile can be obtained. Applying this method, there are obtained data sets which allow the feedrate scheduling so that the uncut chip area is constant and, as a result, the cutting force is constant, which allows to use more efficiently the machine tool and to obtain the reduction of machining time.

Keywords: Reconfigurable machine tool, system identification, uncut chip area, cutting conditions scheduling.

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Authors: S. Y. Lin, C. H. Kuan, C. H. She, W. T. Wang

Abstract:

In this study, ultrasonic assisted machining (UAM) technique is applied in side-surface milling experiment for glass-ceramic workpiece material. The tungsten carbide cutting-tool with diamond coating is used in conjunction with two kinds of cooling/lubrication mediums such as water-soluble (WS) cutting fluid and minimum quantity lubricant (MQL). Full factorial process parameter combinations on the milling experiments are planned to investigate the effect of process parameters on cutting performance. From the experimental results, it tries to search for the better process parameter combination which the edge-indentation and the surface roughness are acceptable. In the machining experiments, ultrasonic oscillator was used to excite a cutting-tool along the radial direction producing a very small amplitude of vibration frequency of 20KHz to assist the machining process. After processing, toolmaker microscope was used to detect the side-surface morphology, edge-indentation and cutting tool wear under different combination of cutting parameters, and analysis and discussion were also conducted for experimental results. The results show that the main leading parameters to edge-indentation of glass ceramic are cutting depth and feed rate. In order to reduce edge-indentation, it needs to use lower cutting depth and feed rate. Water-soluble cutting fluid provides a better cooling effect in the primary cutting area; it may effectively reduce the edge-indentation and improve the surface morphology of the glass ceramic. The use of ultrasonic assisted technique can effectively enhance the surface finish cleanness and reduce cutting tool wear and edge-indentation. 

Keywords: Glass-ceramic, ultrasonic assisted machining, cutting performance, edge-indentation

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Authors: M. A. Kamely, A. Y. Bani Hashim, S. H. Yahaya, H. Sihombing, H. Hazman

Abstract:

Grinding requires high specific energy and the consequent development of high temperature at tool-workpiece contact zone impairs workpiece quality by inducing thermal damage to the surface. Finishing grinding process requires component to be cut more than one pass. This paper deals with an investigation on the effect of multipass cutting on grinding performance in term of surface roughness and surface defect. An experimental set-up has been developed for this and a detailed comparison has been done with a single pass and various numbers of cutting pass. Results showed that surface roughness increase with the increase in a number of cutting pass. Good surface finish of 0.26μm was obtained for single pass cutting and 0.73μm for twenty pass cutting. It was also observed that the thickness of the white layer increased with the increased in a number of cutting pass.

Keywords: Cylindrical grinding, Multipass cutting, Surface roughness, Surface defect.

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Authors: M.Davami, M.Zadshakoyan

Abstract:

Production of hard-to-cut materials with uncoated carbide cutting tools in turning, not only cause tool life reduction but also, impairs the product surface roughness. In this paper, influence of hot machining method were studied and presented in two cases. Case1-Workpiece surface roughness quality with constant cutting parameter and 300 ºC initial workpiece surface temperature. Case 2- Tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min). The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10(SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300 ºC, causing reduction of yield stress about 15%. Results obtained experimentally, show that the method used can considerably improved surface quality of the workpiece.

Keywords: Hard-to-cut material, Hot machining, Surfaceroughness, Tool Temperature

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Authors: Tadahiro Wada, Hiroyuki Hanyu

Abstract:

In this study, to clarify the effectiveness of an aluminum/chromium/tungsten-based-coated tool for cutting sintered steel, tool wear was experimentally investigated. The sintered steel was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and (Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the physical vapor deposition (PVD) method. Moreover, the tool wear of the aluminum/chromium/tungsten-based-coated item was compared with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool wear mechanism of the aluminum/chromium/tungsten-coating film for cutting sintered steel, Scanning Electron Microscope observation and Energy Dispersive x-ray Spectroscopy mapping analysis were conducted on the abraded surface. The following results were obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated tool was the slowest among that of the five coated tools. (2) Adding carbon (C) to the aluminum/chromium/tungsten-based-coating film was effective for improving the wear-resistance. (3) The main wear mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)- and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.

Keywords: Cutting, physical vapor deposition coating method, tool wear, tool wear mechanism, sintered steel.

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Authors: M. Jalali Azizpour, H. Mohammadi majd

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In this paper, the wear of high speed steel hobs during hobbing has been studied. The wear mechanisms are strongly influenced by the choice of cutting speed. At moderate and high cutting speeds three major wear mechanisms were identified: abrasion, mild adhesive and severe adhesive. The microstructure and wear behavior of two high speed steel grades (M2 and ASP30) has been compared. In contrast, a variation in chemical composition or microstructure of HSS tool material generally did not change the dominant wear mechanism. However, the tool material properties determine the resistance against the operating wear mechanism and consequently the tool life. The metallographic analysis and wear measurement at the tip of hob teeth included scanning electron microscopy and stereoscope microscopy. Roughness profilometery is used for measuring the gear surface roughness.

Keywords: abrasion, adhesion, cutting speed, hobbing, wear mechanism

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Authors: Murat Sarıkaya, Abdulkadir Güllü

Abstract:

Haynes 25 alloy (also known as L-605 alloy) is cobalt based super alloy which has widely applications such as aerospace industry, turbine and furnace parts, power generators and heat exchangers and petroleum refining components due to its excellent characteristics. However, the workability of this alloy is more difficult compared to normal steels or even stainless. In present work, an experimental investigation was performed under cryogenic cooling to determine cutting tool wear patterns and obtain optimal cutting parameters in turning of cobalt based superalloy Haynes 25. In experiments, uncoated carbide tool was used and cutting speed (V) and feed rate (f) were considered as test parameters. Tool wear (VBmax) were measured for process performance indicators. Analysis of variance (ANOVA) was performed to determine the importance of machining parameters.

Keywords: Cryogenic machining, difficult-to-cut alloy, tool wear, turning.

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Authors: C. Bisu, M. Zapciu, A. Gérard

Abstract:

This paper proposes a method to vibration analysis in order to on-line monitoring and predictive maintenance during the milling process. Adapting envelope method to diagnostics and the analysis for milling tool materials is an important contribution to the qualitative and quantitative characterization of milling capacity and a step by modeling the three-dimensional cutting process. An experimental protocol was designed and developed for the acquisition, processing and analyzing three-dimensional signal. The vibration envelope analysis is proposed to detect the cutting capacity of the tool with the optimization application of cutting parameters. The research is focused on Hilbert transform optimization to evaluate the dynamic behavior of the machine/ tool/workpiece.

Keywords: diagnostics, envelope, milling, vibration

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Authors: S. M. Ali, N. R. Dhar

Abstract:

Tool wear and surface roughness prediction plays a significant role in machining industry for proper planning and control of machining parameters and optimization of cutting conditions. This paper deals with developing an artificial neural network (ANN) model as a function of cutting parameters in turning steel under minimum quantity lubrication (MQL). A feed-forward backpropagation network with twenty five hidden neurons has been selected as the optimum network. The co-efficient of determination (R2) between model predictions and experimental values are 0.9915, 0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra respectively. The results imply that the model can be used easily to forecast tool wear and surface roughness in response to cutting parameters.

Keywords: ANN, MQL, Surface Roughness, Tool Wear.

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Authors: Othman Belgassim, Krzysztof Jemielniak

Abstract:

The analysis of Acoustic Emission (AE) signal generated from metal cutting processes has often approached statistically. This is due to the stochastic nature of the emission signal as a result of factors effecting the signal from its generation through transmission and sensing. Different techniques are applied in this manner, each of which is suitable for certain processes. In metal cutting where the emission generated by the deformation process is rather continuous, an appropriate method for analysing the AE signal based on the root mean square (RMS) of the signal is often used and is suitable for use with the conventional signal processing systems. The aim of this paper is to set a strategy in tool failure detection in turning processes via the statistic analysis of the AE generated from the cutting zone. The strategy is based on the investigation of the distribution moments of the AE signal at predetermined sampling. The skews and kurtosis of these distributions are the key elements in the detection. A normal (Gaussian) distribution has first been suggested then this was eliminated due to insufficiency. The so called Beta distribution was then considered, this has been used with an assumed β density function and has given promising results with regard to chipping and tool breakage detection.

Keywords: AE signal, skew, kurtosis, tool failure

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Authors: David Downey

Abstract:

With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical, aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: Additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear.

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Authors: S. Ghorbani, N. I. Polushin

Abstract:

The machinability of workpieces (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron) in turning operation has been carried out using different types of cutting tool (conventional, cutting tool with holes in toolholder and cutting tool filled up with composite material) under dry conditions on a turning machine at different stages of spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). Experimentation was performed as per Taguchi’s orthogonal array. To evaluate the relative importance of factors affecting surface roughness the single decision tree (SDT), Decision tree forest (DTF) and Group method of data handling (GMDH) were applied.

Keywords: Decision Tree Forest, GMDH, surface roughness, taguchi method, turning process.

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Authors: M. Amrita, R. R. Srikant, A. V. Sita Rama Raju

Abstract:

Water miscible cutting fluids are conventionally used to lubricate and cool the machining zone. But issues related to health hazards, maintenance and disposal costs have limited their usage, leading to application of Minimum Quantity Lubrication (MQL). To increase the effectiveness of MQL, nanocutting fluids are proposed. In the present work, water miscible nanographite cutting fluids of varying concentration are applied at cutting zone by two systems A and B. System A utilizes high pressure air and supplies cutting fluid at a flow rate of 1ml/min. System B uses low pressure air and supplies cutting fluid at a flow rate of 5ml/min. Their performance in machining is evaluated by measuring cutting temperatures, tool wear, cutting forces and surface roughness and compared with dry machining and flood machining. Application of nanocutting fluid using both systems showed better performance than dry machining. Cutting temperatures and cutting forces obtained by both techniques are more than flood machining. But tool wear and surface roughness showed improvement compared to flood machining. Economic analysis has been carried out in all the cases to decide the applicability of the techniques.

Keywords: Economic analysis, Machining, Minimum Quantity lubrication, nanofluid.

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Authors: M. S. Said, J. A. Ghani, Che Hassan C. H., N. N. Wan, M. A. Selamat, R. Othman

Abstract:

Metal matrix composites (MMCs) attract considerable attention as a result from its ability in providing a high strength, high modulus, high toughness, high impact properties, improving wear resistance and providing good corrosion resistance compared to unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been widely used in various industrial sectors such as in transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is an MMC that had been reinforced with aluminium nitrate (AlN) particle and become a new generation material use in automotive and aerospace sector. The AlN is one of the advance material that have a bright prospect in future since it has features such as lightweight, high strength, high hardness and stiffness quality. However, the high degree of ceramic particle reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density is the main problem which leads to difficulties in machining process. This paper examined the tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 (Titanium diboride) coated carbide cutting tool. The volume of the AlN reinforced particle was 10% and milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were at the cutting speed of (230, 300 and 370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The Sometech SV-35 video microscope system used to quantify of the tool wear. The result shown that tool life span increasing with the cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at 0.4mm) which constituted an optimum condition for longer tool life lasted until 123.2 mins. Meanwhile, at medium cutting speed which at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we found that tool life span lasted until 119.86 mins while at low cutting speed it lasted in 119.66 mins. High cutting speed will give the best parameter in cutting AlSi/AlN MMCs material. The result will help manufacturers in machining process of AlSi/AlN MMCs materials.

Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, TiB2 coated cemented carbide tool.

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Authors: V. Prasannavenkadesan, A. Elango, S. Chockalingam

Abstract:

During machining process, chatter is an unavoidable phenomenon. Boring bars possess the cantilever shape and due to this, it is subjected to chatter. The adverse effect of chatter includes the increase in temperature which will leads to excess tool wear. To overcome these problems, in this investigation, Cartridge brass (Cu – 70% and Zn – 30%) is passively fixed on the boring bar and also clearance is provided in order to reduce the displacement, tool wear and cutting temperature. A conventional all geared lathe is attached with vibrometer and pyrometer is used to measure the displacement and temperature. The influence of input parameters such as cutting speed, depth of cut and clearance on temperature, tool wear and displacement are investigated for various cutting conditions. From the result, the optimum conditions to obtain better damping in boring process for chatter reduction is identified.

Keywords: Boring, chatter, mass damping, passive damping.

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Authors: A. Samraj, S. Sayeed, J. E. Raja., J. Hossen, A. Rahman

Abstract:

Monitoring the tool flank wear without affecting the throughput is considered as the prudent method in production technology. The examination has to be done without affecting the machining process. In this paper we proposed a novel work that is used to determine tool flank wear by observing the sound signals emitted during the turning process. The work-piece material we used here is steel and aluminum and the cutting insert was carbide material. Two different cutting speeds were used in this work. The feed rate and the cutting depth were constant whereas the flank wear was a variable. The emitted sound signal of a fresh tool (0 mm flank wear) a slightly worn tool (0.2 -0.25 mm flank wear) and a severely worn tool (0.4mm and above flank wear) during turning process were recorded separately using a high sensitive microphone. Analysis using Singular Value Decomposition was done on these sound signals to extract the feature sound components. Observation of the results showed that an increase in tool flank wear correlates with an increase in the values of SVD features produced out of the sound signals for both the materials. Hence it can be concluded that wear monitoring of tool flank during turning process using SVD features with the Fuzzy C means classification on the emitted sound signal is a potential and relatively simple method.

Keywords: Fuzzy c means, Microphone, Singular ValueDecomposition, Tool Flank Wear.

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Authors: M. Azadbakht, A. Rezaei Asl, K. Tamaskani Zahedi

Abstract:

Corn is cultivated in most countries because of high consumption, quality, and food value. This study evaluated needed energy for cutting corn stems in different levels of cutting height and moisture content. For this reason, test device was fabricated and then calibrated. The device works on the principle of conservation of energy. The results were analyzed using split plot design and SAS software. The results showed that effect of height and moisture content and their interaction effect on cutting energy are significant (P<1%). The maximum cutting energy was 3.22 kJ in 63 (w.b.%) moisture content and the minimum cutting energy was 1.63 kJ in 83.25 (w.b.%) moisture content.

Keywords: Cutting energy, Corn stalk, Cutting height, Moisture content, Impact cutting.

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Authors: M. Sadilek, L. Petrkovska, J. Kratochvil

Abstract:

The article deals with the possibilities of increasing the efficiency of turning thin-walled workpieces. It proposes a new strategy for turning and it proposes new implementation of roughing cycles where a variable depth of cut is applied. Proposed roughing cycles are created in the CAD/CAM system. These roughing cycles are described in relation to their further use in practice.

The experimental research has focused on monitoring the durability of cutting tool and increases its tool life. It compares the turning where the standard roughing cycle is used and the turning where the proposed roughing cycle with variable depth of cut is applied. In article are monitored tool wear during cutting with the sintered carbide cutting edge. The result verifies theoretical prerequisites of tool wear.

Keywords: Variable depth of cut, CAD-CAM system, turning, durability.

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Authors: Abdulhamit Donder, Erhan Ilhan Konukseven

Abstract:

Grinding operation is performed in order to obtain desired surfaces precisely in machining process. The needed relative motion between the cutting tool and the workpiece is generally created either by the movement of the cutting tool or by the movement of the workpiece or by the movement of both of them as in our case. For all these cases, the coherence level between the movements and the interaction forces is a key influential parameter for efficient grinding. Therefore, in this work, spectral coherence analysis has been performed to investigate the coherence level between grinding interaction forces and the movement of the workpiece on our robotic-grinding experimental setup in METU Mechatronics Laboratory.

Keywords: Coherence analysis, correlation, FFT, grinding, Hanning window, machining, Piezo actuator, reverse arrangements test, spectral analysis.

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Authors: Z. Rihova, K. Saksl, C. Siemers, D. Ostroushko

Abstract:

Titanium alloys like the modern alloy Ti 6Al 2Sn 4Zr 6Mo (Ti-6246) combine excellent specific mechanical properties and corrosion resistance. On the other hand,due to their material characteristics, machining of these alloys is difficult to perform. The aim of the current study is the analyses of wear mechanisms of coated cemented carbide tools applied in orthogonal cutting experiments of Ti-6246 alloy. Round bars were machined with standard coated tools in dry conditions on a CNC latheusing a wide range of cutting speeds and cutting depths. Tool wear mechanisms were afterwards investigated by means of stereo microscopy, optical microscopy, confocal microscopy and scanning electron microscopy. Wear mechanisms included fracture of the tool tip (total failure) and abrasion. Specific wear features like crater wear, micro cracks and built-up edgeformation appeared depending of the mechanical and thermal conditions generated in the workpiece surface by the cutting action.

Keywords: Alloy 6246, machining, tool wear, optical microscopy, SEM, EDX analysis

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Authors: Lorenzo Daghini, Andreas Archenti, Cornel Mihai Nicolescu

Abstract:

This paper introduces a novel design for boring bar with enhanced damping capability. The principle followed in the design phase was to enhance the damping capability minimizing the loss in static stiffness through implementation of composite material interfaces. The newly designed tool has been compared to a conventional tool. The evaluation criteria were the dynamic characteristics, frequency and damping ratio, of the machining system, as well as the surface roughness of the machined workpieces. The use of composite material in the design of damped tool has been demonstrated effective. Furthermore, the autoregressive moving average (ARMA) models presented in this paper take into consideration the interaction between the elastic structure of the machine tool and the cutting process and can therefore be used to characterize the machining system in operational conditions.

Keywords: ARMA, cutting stability, damped tool, machining.

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Authors: Samy E. Oraby, Ayman M. Alaskari

Abstract:

The importance of machining process in today-s industry requires the establishment of more practical approaches to clearly represent the intimate and severe contact on the tool-chipworkpiece interfaces. Mathematical models are developed using the measured force signals to relate each of the tool-chip friction components on the rake face to the operating cutting parameters in rough turning operation using multilayers coated carbide inserts. Nonlinear modeling proved to have high capability to detect the nonlinear functional variability embedded in the experimental data. While feedrate is found to be the most influential parameter on the friction coefficient and its related force components, both cutting speed and depth of cut are found to have slight influence. Greater deformed chip thickness is found to lower the value of friction coefficient as the sliding length on the tool-chip interface is reduced.

Keywords: Mathematical modeling, Cutting forces, Frictionforces, Friction coefficient and Chip ratio.

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Authors: Panagiotis Kyratsis, Konstantinos Kakoulis

Abstract:

Nowadays, the rapid development of CAD systems’ programming environments results in the creation of multiple downstream applications, which are developed and becoming increasingly available. CAD based manufacturing simulations is gradually following the same trend. Drilling is the most popular holemaking process used in a variety of industries. A specially built piece of software that deals with the drilling kinematics is presented. The cutting forces are calculated based on the tool geometry, the cutting conditions and the tool/work-piece materials. The results are verified by experimental work. Finally, the response surface methodology (RSM) is applied and mathematical models of the total thrust force and the thrust force developed because of the main cutting edges are proposed.

Keywords: Application programming interface, CAD, drilling, response surface methodology, RSM.

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Authors: S. Srikiran, Dharmala Venkata Padmaja, P. N. L. Pavani, R. Pola Rao, K. Ramji

Abstract:

Technological advancements in the development of cutting tools and coolant/lubricant chemistry have enhanced the machining capabilities of hard materials under higher machining conditions. Generation of high temperatures at the cutting zone during machining is one of the most important and pertinent problems which adversely affect the tool life and surface finish of the machined components. Generally, cutting fluids and solid lubricants are used to overcome the problem of heat generation, which is not effectively addressing the problems. With technological advancements in the field of tribology, nano-level particulate solid lubricants are being used nowadays in machining operations, especially in the areas of turning and grinding. The present investigation analyses the effect of using nano-particulate graphite powder as lubricant in the turning of AISI 1040 steel under variable machining conditions and to study its effect on cutting forces, tool temperature and surface roughness of the machined component. Experiments revealed that the increase in cutting forces and tool temperature resulting in the decrease of surface quality with the decrease in the size of nano-particulate graphite powder as lubricant.

Keywords: Solid lubricant, graphite, minimum quantity lubrication, nanoparticles.

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Authors: Panagiotis Kyratsis, Dr. Ing. Nikolaos Bilalis, Dr. Ing. Aristomenis Antoniadis

Abstract:

Twist drills are geometrical complex tools and thus various researchers have adopted different mathematical and experimental approaches for their simulation. The present paper acknowledges the increasing use of modern CAD systems and using the API (Application Programming Interface) of a CAD system, drilling simulations are carried out. The developed DRILL3D software routine, creates parametrically controlled tool geometries and using different cutting conditions, achieves the generation of solid models for all the relevant data involved (drilling tool, cut workpiece, undeformed chip). The final data derived, consist a platform for further direct simulations regarding the determination of cutting forces, tool wear, drilling optimizations etc.

Keywords: Drilling, CAD based simulation, 3D-modelling.

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Authors: Majid Tolouei-Rad

Abstract:

This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining vibration, and chatter. Case studies reveal the fact that application of this approach could result in a slight increase of machining time, however, a considerable reduction of tooling cost, machining vibration, noise and chatter can be achieved in addition to producing a better surface finish.

Keywords: CNC machines, milling, optimization, removal rate.

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Authors: Guillaume Mullier, Jean François Chatelain

Abstract:

Carbon Fiber Reinforced Plastics (CFRPs) are widely used for advanced applications, in particular in aerospace, automotive and wind energy industries. Once cured to near net shape, CFRP parts need several finishing operations such as trimming, milling or drilling in order to accommodate fastening hardware and meeting the final dimensions. The present research aims to study the effect of the cutting temperature in trimming on the mechanical strength of high performance CFRP laminates used for aeronautics applications. The cutting temperature is of great importance when dealing with trimming of CFRP. Temperatures higher than the glass-transition temperature (Tg) of the resin matrix are highly undesirable: they cause degradation of the matrix in the trimmed edges area, which can severely affect the mechanical performance of the entire component. In this study, a 9.50mm diameter CVD diamond coated carbide tool with six flutes was used to trim 24-plies CFRP laminates. A 300m/min cutting speed and 1140mm/min feed rate were used in the experiments. The tool was heated prior to trimming using a blowtorch, for temperatures ranging from 20°C to 300°C. The temperature at the cutting edge was measured using embedded KType thermocouples. Samples trimmed for different cutting temperatures, below and above Tg, were mechanically tested using three-points bending short-beam loading configurations. New cutting tools as well as worn cutting tools were utilized for the experiments. The experiments with the new tools could not prove any correlation between the length of cut, the cutting temperature and the mechanical performance. Thus mechanical strength was constant, regardless of the cutting temperature. However, for worn tools, producing a cutting temperature rising up to 450°C, thermal damage of the resin was observed. The mechanical tests showed a reduced mean resistance in short beam configuration, while the resistance in three point bending decreases with increase of the cutting temperature.

Keywords: Composites, Trimming, Thermal Damage, Surface Quality.

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Authors: Vladimir Aleksandrovich Rogov, Ghorbani Siamak

Abstract:

Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbide cutting insert coated with TiC. Turning experiments were planned by Taguchi method L₉ orthogonal array.Three levels for spindle speed, feed rate, depth of cut and tool overhang were chosen as cutting variables. The obtained experimental data has been analyzed using signal to noise ratio and analysis of variance. The main effects have been discussed and percentage contributions of various parameters affecting surface roughness and natural frequency, and optimal cutting conditions have been determined. Finally, optimization of the cutting parameters using Taguchi method was verified by confirmation experiments.

Keywords: Turning, Cutting conditions, Surface roughness, Natural frequency, Taguchi method, ANOVA, S/N ratio.

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Authors: Anjan Kumar Kakati, M. Chandrasekaran, Amitava Mandal, Amit Kumar Singh

Abstract:

End milling process is one of the common metal cutting operations used for machining parts in manufacturing industry. It is usually performed at the final stage in manufacturing a product and surface roughness of the produced job plays an important role. In general, the surface roughness affects wear resistance, ductility, tensile, fatigue strength, etc., for machined parts and cannot be neglected in design. In the present work an experimental investigation of end milling of aluminium alloy with carbide tool is carried out and the effect of different cutting parameters on the response are studied with three-dimensional surface plots. An artificial neural network (ANN) is used to establish the relationship between the surface roughness and the input cutting parameters (i.e., spindle speed, feed, and depth of cut). The Matlab ANN toolbox works on feed forward back propagation algorithm is used for modeling purpose. 3-12-1 network structure having minimum average prediction error found as best network architecture for predicting surface roughness value. The network predicts surface roughness for unseen data and found that the result/prediction is better. For desired surface finish of the component to be produced there are many different combination of cutting parameters are available. The optimum cutting parameter for obtaining desired surface finish, to maximize tool life is predicted. The methodology is demonstrated, number of problems are solved and algorithm is coded in Matlab®.

Keywords: End milling, Surface roughness, Neural networks.

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