The development of manufacturing technology is mostly given by economics, environmental trends and the development of cutting materials and machine tools. Manufacturing is a significant part of the worldwide economy. Machining (material removal processes) represents major part of production costs. This paper yield inquiries into the hard and precise milling with a focus on force effects in experimental machining, tool wear and final surface qualities (roughness, micro hardness). The precision machining of hardened steel differs from conventional machining in terms of the hardness of the workpiece materials and the cutting tool materials that are required. Hard materials are characterized by high hardness (> 45 HRC) and abrasiveness. Machining processes require cutting tools of much higher hardness and also higher resistance of the abrasive wear. Recently developed cubic boron nitride (CBN) and coated sintered carbides cutting tools are considered to have the ability of cutting such as steel. CBN cutting tools show good performance during machining of the hardened steel because of their hot hardness and good fracture toughness.
Requirements for flexib le manufacturing have been increasing in the last years. In order to insure effective operation of expansive manufacturing equip ment, wh ich has to run automatically and unattended, tool monitoring is important. Therefore, the essential problem to be overcome to achieve the full potential of un manned mach ining is the development of effective and reliable sensors system to monitor the process and corrective actions in case abnormal operation. The ultimate goal of the develop ment of such production equipment is to enhance the overall economic of the manufacturing process. Even when there are at present many monitoring systems co mmercially available in the market for turning processes, serious difficulties still remain to be solved to apply monitoring systems successfully in machining centres. Being these difficult ies main ly related with the limited accessibility to the rotating tool for sensing purposes in tool driven machin ing processes. Therefore, the primary objective o f this paper assess the feasibility of using force signal analysis as means for monitoring tool condition in drilling
Utilization off orce signals to a chieve on line drill wear monitoring is presented in this paper. After consulting the available literature it is obvious, that only some features of force component are proposedfor drill wear monitoring .The really important task in drilling operations is to avoid catastrophic failure. It is desirable to make the most economic use the cutting tool without reaching catastrophic failure. Traditionally, the usual approach to tool monitoring the drilling was to the detect breakage as fast as possible and avoid overloads in the machine tool. These strategies are not enough to ensure the optimum economic pe$ormance ofthe machiningprocess.Therefore, the primary objective of this lecture assesses the feasibility of using force signature analysis as means for monitoring tool wear.
Usually, the coatings used in industrial applications require post-processing to reach their final shape. However, some of these coatings are difficult-to-cut, mainly because of their high hardness. The present study provides a revision of some experimental investigations on the turning of WC-Co, Stellite, and Fe-based and NiAl alloys. The materials are used for both coatings and sintered workpieces providing insights for conducting turning tests. For the success of the turning process, the selection of the machining parameters is a critical issue. Based on the reviewed investigations, the surface roughness is clearly influenced by the feed rate, expecting higher values than the ones predicted by the theoretical equations. Besides, the increase of both the cutting speed and feed rate leads to a high tool wear. Likewise, the increase of the feed rate leads to higher machining forces. In general, the influence of the cutting speed and depth of cut is less evident. Regarding the machining parameters, usually their maximum values are fixed at low levels: 100 m/min, 0.35 mm/rev and 0.3 mm, for the cutting speed, feed rate and depth of cut, respectively.
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