Papers by Keyword: Tool Wear

Abstract: The basic hypothesis of this article focuses on the study changes in mechanical properties of stainless steels ELC X01Cr18Ni10Ti under surface finish when drilling. The problem of drilling holes with diameter D=3 to 10 mm resides in the fact that 30 to 40% of these holes do not comply with prescribed requested requirements1. This article presents the results of experiments focusing on the study of the damage process in helical drills with diameter d=6.0 mm when drilling into austenitic stainless steel ELC X01Cr18Ni10Ti. This study also includes an analysis of accompanying phenomena in the cutting zone by measuring some selected parameters.

Abstract: In this report, our attention was paid on the tool wear due to the stop of tool-feed, caused by change from the automatic operation to the manual one in the lathe work, because it was thought that skill level of workers influences the tool wear significantly. First, the workers gaze-point movement was recorded with an eye camera and analyzed with the application software. The results showed that the stop time of the tool-feed for skilled workers was very shorter than that of beginners. Then, the relationship between the tool-feed stop time and the tool wear was investigated by using an NC lathe. It was found that the shorter the stop time is, the smaller the tool wear becomes. Based on the above findings, the influence of the skill level on the tool wear due to the tool-feed stop in lathe work was revealed and key issues in the skill transfer of lathe work were confirmed.

Abstract: In this paper an experimental study in milling of SiCp/Al composites on a high precision machine was carried out by using TiN coated tools, TiAlN coated tools and carbide tools. The result of tool wear was observed and measured by an optical microscope and a scanning electron microscope (SEM). The results show that the main wear mode is the flank wear and the wear mechanism is abrasive wear and adhesive wear for the cutting tools used in the experiment.

Abstract: The foundation of the cutting process rests in the full plastic deformation of the separated material (in the form of chips) at TW, for defined conditions and a defined technological M-F system. Although the cost of the cutting tool makes up only part of the total cost for producing one component piece (8 % to 12 %), they have a significant impact particularly on the following: cutting process TW, machine stand time, number of required operations, period for which the components must stay within the company and number of cutting tools. The basic hypothesis of this article focuses on the study changes in the tool wear during drilling of a new Cast Iron GTW 35-04. The problem of drilling holes with diameter D=4 to 12 mm resides in the fact that 25 to 30% of these holes do not comply with prescribed requested requirements. This article presents the results of experiments focusing on the study of the damage process in helical drills with diameter d=8.0 mm when drilling into a new Cast Iron GTW 35-04. This study also includes an analysis of accompanying phenomena in the cutting zone by measuring some selected parameters.

Abstract: In this paper, the cutting performance of cemented carbide with ultrafine particles using single crystal diamond for tool material in die and mold manufacturing is investigated. The flat work is done using spiral for tool pass. The flat work is divided into small area and middle area. The spiral pitch in addition to depth of cut is changed in flat work. The tool wear is also estimated from form deviation by measuring surface form before and after machining. These results showed that ductile mode cutting was possible and the tool wear could be estimated from surface form. The tool wear was large in proportion to both the depth of cut and cutting length.

Abstract: Experimental research was carried out to analyze the wear patterns of several tools which include high-speed steel (HSS), coated cemented carbide and ceramic tools, and to study the tool wear mechanism in milling resin sand mold materials. The main wear mechanism is abrasive wear and the dominant tool failure mode is flank wear. Different cutting parameters have different influence to the tool wear. In addition, it is essential to select suitable tool material with appropriate hardness. In this paper, the experiment results are contributive to choose proper cutting tool materials and parameters in milling resin sand mold material.

Abstract: Green manufacturing is a method in which products are produced by consuming less energy and natural resources and being safe to employees, consumers, environment and society. This paper presents an experimental study that compares the machining characteristics when a soy-based cutting fluid and petroleum-based alternate are used in turning medium and high carbon alloy steels. The result of the study will provide reference for cutting fluid management personnel to make proper decision to substitute traditional cutting fluids with the environment-friendly product.

Abstract: The basic hypothesis of this article focuses on the study changes in the tool wear during drilling of stainless steels ELC X04Cr18Ni9Ti. The problem of drilling holes with diameter D=2 to 8 mm resides in the fact that 20 to 30% of these holes do not comply with prescribed requested requirements. This article presents the results of experiments focusing on the study of the damage process in helical drills with diameter d=8.0 mm when drilling into austenitic stainless steel ELC X04Cr18Ni9Ti. This study also includes an analysis of accompanying phenomena in the cutting zone by measuring some selected parameters.

Abstract: Thermal or heat assisted machining is used to machine hard and difficult-to-machine materials such as Inconel and Titanium alloys. The main concept is that localized surface heating of the work-piece reduces the yield strength of the material significantly, making it amenable to plastic deformation and machining. Thus, heat assisted machining has been used for over a century. However, the heating technique and temperature are very much dependent on the type of working material. Therefore, a multitude of heating techniques has been applied over the years including Laser Assisted Machining (LAM) and Plasma Enhanced Machining (PEM) in the industry. But such processes are very expensive and have not been found in wide scale applications. The authors of the current research have therefore looked into the application of a simple Tungsten Inert Gas (TIG) welding setup to perform heat assisted turning of AISI 304 Stainless Steel. Such welding equipment is relatively cheap and available. Also, stainless steel is perennially used in the industry for high strength applications. Hence, it is very important to determine with optimal cutting temperature when applying a TIG setup for heat assisted machining of stainless steel. This paper describes three separate techniques for determining the optimum temperature. All three processes applied the same experimental setup but used different variables for evaluating the best temperature. The first process used vibration amplitude reduction with increment in temperature to identify the desired temperature. The second process used chip shrinkage coefficient to locate the same temperature. And finally, the third process investigated tool wear as a criterion for determining the optimum temperature. In all three cases the three primary cutting parameters: cutting speed, feed, and depth of cut, were varied in the same pattern. The results obtained from all three approaches showed that 450oC was undoubtedly the best temperature for heat assisted machining of stainless steel.

Abstract: Machining of Carbon Fibre Composites (CFCs) particularly drilling, is frequently employed in industry especially when dealing with joining, assembly and structural repair of the parts. However, the nature and heterogeneous structure of CFCs often results in rapid wear of the cutting tool. This research studied the relationship and compared the effect of drilling a CFC plaque without cutting fluid, with conventional cutting fluid and with cryogenic cooling at constant cutting speed of 94 m/min and feed rate of 0.065 mm/revolution using tungsten carbide twist drill. The conventional cutting fluid was supplied continuously to the drill and the CFC plaque during the drilling cycle; while for the cryogenic cooling tests, the drill tip was immersed in liquid nitrogen for 10 and 30 seconds prior to drilling the CFC. It was found that the tool wear increased with the increasing number of drilled holes at all machining conditions. After drilling of 325 holes, the largest tool wear observed was 181 μm which was produced when drilling the CFC plaque with conventional cutting fluid. The corresponding tool wear for drilling with cryogenic cooling was 164 μm and the smallest tool wear of 155 μm was observed during dry drilling. Dry drilling produced the smallest tool wear because the heat generated reduced the strength of the CFC, particularly polymer matrix. Therefore, this situation led to easier machining of CFC materials; consequently reduced the wear of the tool.