Papers by Keyword: Tool Wear

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Authors: Cai Xu Yue, Xian Li Liu, Hong Min Pen, Jing Shu Hu, Xing Fa Zhao
Abstract: Tool wear plays an important part during cutting process, and wear loss has a close relationship with cutting condition, which affects machined surface mostly. In order to accomplish tool wear prediction in way of FEM, based on founding of cutting model under steady state, interrelated parameters needed for tool wear prediction, such as cutting temperature, contact pressure and raletive sliding velocity are extracted. By compiling Python subprogram and using Abaqus tool in hard cutting process PCBN tool wear is predicted, which provide foundation for optimizing cutting condition.
Authors: Fu Gang Yan, Cai Xu Yue, Xian Li Liu, Yu Fu Li, Shu Yi Ji
Abstract: Tool wear plays an important role in cutting process research. It affects the quality of machined surface and cutting parameter to a great extent, such as cutting force, cutting temperature and cutting quiver. In order to predict tool wear in hard cutting process by using FEM method, the character of tool wear during cutting process is presented firstly, and Usui’s tool wear rate model is introduced. Then the FEM model for steady state cutting process using Abaqus is established. FEM model describes the workpiece material characteristic accurately for the process of PCBN tool cutting GCr15 by adoptiving Johnson-Cook constitutive model. Simulation results of steady cutting process offer foundation to simulate tool wear.
Authors: Kyung Hee Park, Dong Yoon Lee, Ki Hyeong Song, Seok Woo Lee
Abstract: An FE model can be usedfor better understanding the micro cutting process. To identify an edge wear effect, the cutting forces and contact stress on the cutting tool were measured as edge wear progress. On the other hand, a series of orthogonal cutting tests was also carried out forcomparisonwith FEM simulation results in termsof chip formation and cutting forces. A scanning electron microscope (SEM) was used to observe the tools and chips for the purpose of taking measurements. A Kistler dynamometer was also utilized for cutting forces measurement. The FEM micro cutting simulation showed good agreement with experimentalresults in terms of the cutting forces and chip formation. And it was observed in both FEM simulations and experiments that larger edge wear caused higher cutting forces.
Authors: Vlad Diciuc
Abstract: Ball nose end mills are being extensively used for 3-5 axes milling processes but research is still being conducted on the behavior of this type of tool and on the factors that influence its lifespan. The current paper presents the comparative study results of the tool wear, tool life and machined surface quality when 4 axes milling and 5 axes milling annealed C45 workpiece.
Authors: Pramote Poonayom, Voraya Wattanajitsiri, Kittipong Kimapong
Abstract: The feasibility study of the face-milling performance of hard-facing weld metal on JIS-S50C carbon steel was investigated on microstructure, chip characteristics, wear properties, and surface roughness. Discontinuous chips were found in all machining conditions. No buffering weld metal (No buffering layer, NBL) produces longer and thicker chips than that of the buffering weld metal (Buffering layer, BL). The flank wear of the cutting tool edge increases with the cutting length of the test specimen. The maximum wear of 850 mm was found in a wet condition of the NBL weld metal which is about 4 times higher than that of the base metal. High hardness value of the NBL weld metal produces a higher flank wear of the cutting tool edge than that of the BL weld metal. After comparing the wear of the cutting tool edge in wet and dry conditions, it was found that the dry condition exhibits a smaller flank wear than that of the wet condition. In the wet condition, more amount of coolant oil droplets cannot penetrate into the chip-tool interface and then provides an insufficient amount of lubricant in order to decrease the cutting temperature. Therefore wet condition produces severe wear of the cutting.
Authors: Satoru Maegawa, Yuta Morikawa, Shinya Hayakawa, Fumihiro Itoigawa, Takashi Nakamura
Abstract: This paper presents a novel concept for extending the life of the tools that are used in the milling process of carbon-fiber-reinforced plastic (CFRP) composites. Three types of tools were compared in milling tests; tool I: an uncoated tungsten carbide (WC-Co) tool, tool II: a polycrystalline diamond (PCD) tool, and tool III: a combination tool comprising a PCD layer surface with a thickness of 100 μm and a WC-Co substrate flank surface. The measurement of changes in cutting forces over cutting distance revealed that tool III had a better (tool) life performance than the other tools. Additionally, observation of changes in the edge profiles of the tools revealed that the effective edge sharpness of tool III remains constant during the milling tests. The difference between the wear rates of the PCD rake and WC-Co flank surfaces in tool III maintained a constant effective sharpness during the milling process, and it extended the tool life. Based on our findings, we concluded that using the difference between the wear rates of rake and flank surfaces is an effective technique for tool life extension in the milling process of CFRP laminates.
Authors: Guo Qing Zhang, Suet To
Abstract: Tool wear measurement has drawn a significant of attention in the past decades. However, no research has been found on the investigation of tool wear measurement in ultra-precision raster milling (UPRM) process since it is a relative complex cutting process. In the present study, tool wear characteristics were identified by using cutting chip morphologies and a groove cutting. Tool wear investigation using cutting chips is effective because diamond tool wear characteristics can be directly imprinted on the cutting chip surface. Through the inspection of chip surfaces, the profile and location of the tool fracture can be identified. Also, through the groove cutting, the cutting edge retreat due to the tool flank wear can be identified. In this research, a mathematical model was established to calculate the tool retreat. The experimental result shows that the proposed tool wear investigation method is an effective method.
Authors: D. Anjaiah, Raviraj Shetty, R. Pai, M.V. Kini, S.S. Rao
Abstract: Metal matrix composites (MMCs) have been found to possess tremendous prospective engineering applications that require materials offering a combination of lightweight with considerably enhanced mechanical and physical properties. However, the applications of MMCs are limited by their poor machinability which is a result of their highly abrasive nature that causes excessive wear to the cutting tools. In this study, an investigation into the mechanism of the tool wear in cutting of MMCs is carried out. It is found that during cutting of an MMC, the tool cutting edge will impact on the reinforcement particles. The impacted particles will then either be dislodged from the matrix, doing no harm to the tool, or be embedded into the matrix, ploughing on the tool flank and causing excessive tool flank wear. According to this tool wear mechanism, a pressured steam jet approach is developed for the minimization of the tool wear by preventing the impacted reinforcement particles from being embedded in the workpiece matrix. Experimental tests for cutting of SiC–aluminum MMC using cubic boron nitride (KB-90) and polycrystalline diamond (KP-300) tool inserts with the aid of the pressured steam jet are conducted. The results show that from full factorial design of experiments the effect of the pressured steam jet plays a significant role on the tool wear followed by tool inserts and depth of cut. The working mechanism of the pressured steam jet method and the experimental testing results are discussed in detail.
Authors: S. Prabhu, S. Karthik Saran, Debabrata Majumder, Putti Venkata Siva Teja
Abstract: The increase in demand for industrial automation in the manufacturing industry has exposed the significance of machine vision in quality inspection and process monitoring. Contrast to stylus instruments, the computer vision systems have the advantages of being non-contact. In the present study a novel technique has been reviewed to explore various applications of Image processing in inspection of cutting tool surfaces. Measurement and inspection of Surface roughness, Tool wear, Tool profile, Thickness of coating done on tool and Surface defects are all reviewed in this paper which will help in developing a specialized inspection system particularly for inspection of machining tools alone in reduced production cost and minimised time.
Authors: D. Rajeev, D. Dinakaran, Shanmugam Satishkumar, Anselm W.A. Lenin
Abstract: On-line monitoring of tool wear in turning is vital to increase machine utilization as scrapped components, machine tool breakage and unscheduled downtime result from worn tool usage cause huge economic loss. Several techniques have been developed for monitoring wear levels on the cutting tool on-line. Keeping in to account the difficulties encountered during the implementation of tool condition monitoring (TCM). The signal acquisition is one of the key elements used during the implementation of TCM. This paper provides an in depth coverage of various signal acquisition methods used in TCM.
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