Papers by Keyword: Flank Wear

Abstract: This study proposes an automated framework for online cutting tool wear classification in CNC turning using low-cost optical equipment and Convolutional Neural Networks (CNNs). Longitudinal turning experiments were performed on CK45 medium carbon steel using a HAAS TL1 lathe under dry machining conditions. Tool wear evolution was monitored via a lathe-mounted digital microscope, with images classified into three distinct stages: Low (Vb<160 μm), Medium (160≤Vb≤200 μm), and Critical (Vb>200 μm). A shallow CNN architecture, consisting of three convolutional blocks and a Softmax output layer, was developed to balance model complexity with computational efficiency for potential edge deployment. To enhance robustness against positional changes, data augmentation techniques including random translations and rotations were applied. The results demonstrate good performance, with the model achieving 94.7% accuracy and a weighted F1-score of 95.4% on the testing subset. While the model showed exceptional performance in identifying Low and Medium wear, data scarcity in the Critical wear class remained a limiting factor for recall. Overall, the study confirms that shallow CNNs can accurately capture spatial hierarchies for image-based wear assessment.

Abstract: The high-performance machining of difficult-to-cut stainless steel (AISI 316) demands the development and optimization of high-performance tools that can withstand tool load without compromising the surface quality of the components been produced. To justify the optimization feasibility of coated carbide tool in end milling application for good surface quality, a material removal and Productivity approach by evaluating the tool life under optimized cutting condition were carried out in this current research. The objective of this study is to optimize flank tool wear in end milling of AISI 316 using Design of Experiment and box-Behnken method. Tool wear value of 0.174mm was achieved through optimization at low values of feed, speed, and depth of cut. However, an increased feed, depth of cut and speed promised to yield better volume removed in return making tool life to be truncated faster.

Abstract: Enhanced tool life of cutting inserts are most suitable condition for higher productivity of a manufacturing industry. Several methods are found and employed for higher tool life of cutting inserts among which cryogenic treatment is considered as the most significant method but no adequate researches have been found concerning the impact of cryogenic treatment on cermet inserts especially in hard turning operation. Hence, in the current experimental investigation, the comparative assessment of various responses such as flank wear, crater wear, chip morphology, and chip compression ratio were carried out during machining of hardened steel with both untreated and cryo-treated cermet inserts under dry cutting condition. Wear on the rake faces and flank faces were studied using advanced optical microscope, while chip morphology was studied using SEM. The experimental result demonstrated that the uncoated deep cryotreated with tempered cermet insert delivered better results in comparison to other cermet inserts. Deep cryogenically treated with tempered insert was found to be more suitable during machining of hardened steel because of the enhancement of wear resistance, micro hardness and toughness.

Abstract: Polycrystalline cubic boron nitride (cBN), a super-hard material used for hard turning, has good compatibility with steel. However, because chipping occurs from already existing defects and worn out cutting edges, a cBN insert must be exchanged within a short cycle time. By reducing chipping and flank wear, one can reduce the tool costs related to cutting processes and reduce the number of times the insert has to be exchanged, leading to improved productivity. In this study, the authors hypothesize that chipping and flank wear during cutting reduced by polishing a tool edge finely, uniformly, and smoothly before cutting. An apparatus capable of polishing and smoothing a cutting tool edge uniformly is developed. In the free-abrasive control method, application of an AC electric field during polishing is applied to suppress the scattering of abrasives from the tool cutting edge. Results show that scratches created by grinding are nonexistent. Moreover, a smooth cutting edge is obtained after polishing treatment. The wear width of the polished cBN tool under a cutting speed of 50 m/min is half of that of the non-polished treatment tool. Furthermore, no chipping occurs with the polished cBN tool under any conditions. Additionally, results show that the same effect is obtained even when Silicon carbide (SiC) abrasives are used. The n value calculated using the Taylor tool life equation is almost identical in cases of both diamond and SiC abrasives.

Abstract: This study reports an experimental investigation about the wear behavior of TiN and TiCN coated carbide tools during the face milling of pearlitic and ferritic ductile cast iron. Pearlitic ductile cast iron caused the highest cutting forces and flank wear in both TiN and TiCN coated tools. Due to its protective effect, the TiCN coated carbide tool outperformed the TiN coated carbide tool regarding flank wear. The main issue when face milling ferritic ductile cast iron with TiN coated tools was notching wear. The principal reason for notch wear was pointed as adhesive wear caused for the high tendency of ferrite to adhere on the tool. The results demonstrated that the TiCN coating did not showed notching wear when face milling ferritic ductile cast iron, therefore a good choice of coating material can prevent notching wear.

Abstract: Tool wear is an inevitable impediment in machining processes. It is the gradual failure of cutting tools due to regular use. Tool wear affects productivity, dimensional accuracy thereby indirectly representing a significant portion of the machining costs. In this paper, a novel technique has been proposed and adopted with an aim to reduce tool wear. External ultrasonic sound waves were applied in the turning process of mild steel in an attempt to reduce the cutting tool vibration thereby leading to improvements in tool life. In this unique technique ultrasonic sound has been applied from the both sides of the tool holder in the cutting process as waves to reduce tool vibrations and improvement of chip behavior at a certain optimized frequency. Experiments were carried out at 60 KHz ultrasonic frequency to determine the tool wear to the best degree possible. To investigate the cause of ultrasonic effects on tool wear, cutting tool vibration and chip morphology were also studied. The experimental results showed significant improvements in tool wear, vibration and chip behavior.

Abstract: The selection of geometric parameters of cryogenic tap has a direct effect on the reliability of tools and the precision of processed workpiece. Based on nonsubstitute Type-I Censoring Life Tests, a mathematical model in dynamic reliability of cryogenic tap is built, and the change of its reliability is explored. Combined with cutting tool life expansion equation, the effects of geometric parameters on wear life are presented. The results show that of the geometric parameters, rake angle taps in its effect on reliability with the increase in machining time and impact loading action, thus the quality of rake angle should be controlled directly or indirectly so as to reduce its influence on reliability of cutting tool, which can ultimately improve the reliability of cutting tool and the precision of processed workpiece. Meanwhile, the proposed method provides a theoretical basis for improvements of the reliability of tool system.

Abstract: The flank wear and cutting power in the hot turning of Ni-Hard nickel based alloy by carbide tool was investigated in terms of cutting parameters such as cutting speed, feed rate, depth of cut and preheating temperature. Here, the Grey relational based Taguchi optimization method has carried out for optimizing the flank wear and power as output responses. Grey relational grade is obtained by Grey Relational Analysis (GRA) method and by this value the optimum setting parameter has been recognized. The experimental results show that the cutting speed is the most dominant variable and preheating temperature is the least parameter influence the responses.

Abstract: One of the most important issues to be addressed in hard cutting pertains to the evaluation of tool life as it is closely connected to machining quality and overall process cost. The attributes of tool life can be mathematically calculated based on machining conditions and other characteristics of the cutting process. In this paper the formulation developed for CBN tools, applied for the machining of 100Cr6 bearing steel is presented. Experiments were carried out for the validation of the theoretical approach. Additionally, a novel indicator, namely wear intensity, is analyzed and discussed, based on experimental results. Wear intensity is calculated as the ratio of flank wear to cutting length. From the analysis it can be concluded that the prognosis of tool life can be accurate with the proposed method. Furthermore, interesting and useful results are reported in connection to wear intensity and cutting speed in hard cutting.

Abstract: The increase of world requirements for improved products joined to growing competition between companies in the global market makes the same seek processes that ensure lower costs allied to high productivity and high quality product. Therefore, the great industrial and technological development has been increased the search for machining processes that promote, for example, high performance as regards the chip removal, less tool wear, failure and reduced impact on the environment. Regarding nickel-based superalloys, they have an extremely important role in the aeronautical and automotive industries among others. The nickel-based superalloy studied is the Nimonic 80A, hard machine material that has high mechanical strength and corrosion resistance on higher temperatures. The objective of this report is to study the influence of the application of cutting fluids in turning and the machining parameters in order to achieve high performance and optimization of machining this alloy. This one was machined using various machining parameters: cutting speed, feed rate, cutting depth, Minimum Quantity fluid (MQF), and Fluid abundant. After turning chip samples were obtained, was measured the surface roughness, volume of chip removed, cutting length and macro structural, some analyzes were performed and of lifetime of the tools were used in order to detect possible wear, as well as, microstructural observation of the chips by optical microscopy, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS).On this report, we can observe the behavior of the materials and tools in the two cooling conditions used, and also, the impacts of the parameter variations in the surface finish, on the structure of the material and performance of the tools in respect chip removal regarding volume removed and machined length. Application by MQF was promising, but there is an abundant beyond the traditional application.