The study involves coating the high-speed steel (HSS) tool with cubic Boron via electroless nickel co-deposition. The surface coating of Ni-CBN was deposited via electroless nickel where the process of involved chemical reactions as the ceramic CBN powders was embedded within the layer. By introducing the electroless nickel process, the coating cost and procedure could be simplified. The electroless deposition has been extensively practised in industry, and the most prevalent coating offers excellent corrosion, wear and abrasion resistance, ductility, lubricity, electrical properties, and hardness. Thus, the introduction of the new electroless nickel (Ni-CBN) tools can be a contribution to the industry. This paper discussed on comparing the performance of Nickel-cubic boron nitride (Ni-CBN) HSS tool substrates and with uncoated HSS tool for its surface tolerance in milling of Aluminium Alloy 7075. The process variables selected during experimentation based on Taguchi L9 are cutting speed, feed rate, and depth of cut with three different levels for each parameter. Result shows, the lowest flank wear for coated measured is 51.34 μm while the highest is 380.26 μm. The highest surface roughness for uncoated is 1.154 μm and lowest 0.42μm. Meanwhile, for coated substrates, the highest Ra is 0.787μm and lowest 0.251μm. At the end of the analysis, the Ni-CBN HSS cutting tools are generally able to slightly reduce the tool wear with the longest tool lifetime 195 minutes compared uncoated 143 minutes. Therefore, it is concluded that the Ni-CBN HSS tool end mill are generally able to reduce the tool wear.
Ceramic-metal surface coating is very well known for its high thermal, wear and corrosion resistance. The paper discussed on comparison of characterization of Nickel-cubic boron nitride (Ni-CBN) composite coating on two types of substrate. The substrates used are High Speed Steel (HSS) and Carbide due to good hardness, low cost and easily available. The composite Ni-CBN has been used in machining industries recently. It is desirable to get high ceramic of CBN to metal Ni ratio for corrosion, thermal and wear resistance. A sample of HSS and carbide substrate of CBN was used as the base for composite deposition. The surface coating of Ni-CBN was deposited via electroless nickel where the process of involved chemical reactions as the ceramic CBN powders was embedded within the coating. The characterization of the composite deposition was done by JSM-7800F Field Emission Scanning Electron Microscope (FESEM) coupled with Energy Dispersive X-Ray (EDX). The FESEM image proves that nano CBN powders were embedded in HSS substrate and distributed consistently on the coating surface.
Nowadays, coated cutting tools are extensively used in the cutting manufacturing industry, which gets to the important developments in cutting tool performance and economy thru reducing tool wear of cutting tools, low cutting forces, and better-quality surface roughness of the workpiece. From this research, the effects of feed rate, spindle speed and depth of cut on the surface roughness using electroless Nickel-CBN coated cutting tools (carbide) were measured experimentally. The parameters of machining’s setting were determined by using Taguchi’s L9 (33) was used in this study. The S/N ratio with analysis of response in optimization and ANOVA results were used to recognize the best significant parameters affecting the surface finish. From this experiment, the outcome shows that the feed rate parameter most affected to the surface roughness. The optimum setting parameter’s levels are spindle speed 3, feed rate 3, and depth of cut 2. So, the optimum machining settings are spindle speed of 3450 rpm, a feed rate of 334 mm/min, and depth of cut 2 mm.
Purpose: This research aims to analyse the influence of blanking clearance size on the burr development for mild steel sheet, brass and aluminium. The main reason for this research is estimating the burr size on blank parts. It is still significant since the quality of the products is determined by evaluating the amount of allowable burr in the parts. Design/methodology/approach: For the blanking process on the 3.00 mm thick sheets, various sizes of blanking clearance for a 20 mm diameter of the die opening are employed, as is the technique for obtaining the parts. Then the height of the burr on each product was measured using a micrometre and toolmaker microscope. The height of burr for each size of blanking clearance have been recorded and compared using a graph. Comparison made to identify which measure of blanking clearance and which type of material will produce a small size of burr. Findings: For mild steel, brass, and aluminium, blanking clearance 0.15 mm produced burr heights of 0.088 mm, 0.015 mm, and 0.024 mm, and blanking clearance 0.13 mm produced bur heights of 0.192 mm, 0.055 mm, and 0.046 mm, respectively. The brass had a lower burr height than mild steel and aluminium, according to the results. More significant blanking clearance (0.15 mm) produced a smaller size of burr compared to a smaller blanking clearance (0.13 mm). Practical implications: This study focuses on burr height rather than the wear of the punch and die cutting edge; burr height can affect punch and die sharpness. It also can guide practitioners in estimating blanking clearance and the burr height of mild steel, brass and aluminium. Originality/value: This paper demonstrates that the gap between the punch and die influences the burr height. The material strength also affects the burr height, with a high tensile strength resulting in a larger burr.
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