Combined effects of tool surface texturing, cutting parameters and minimum quantity lubrication (MQL) pressure on micro-grinding of BK7 glass

Pratap, Ashwani; Patra, Karali

doi:10.1016/j.jmapro.2020.03.024

Cited by 32 publications

(7 citation statements)

References 28 publications

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“…Machining occurs by melting or vaporizing the material in a certain area by controlled application of high-frequency electrical discharges [ 45 ]. Thus, EDM can create different texture shapes accurately and simply, hence the different texture shapes such as dimples and channels with circular, conical, triangle and D-shapes could be created by the EDM method [ 46 ]. The machined shape in the produced workpiece from the EDM process has an identical replica of the electrode shape [ 47 ], the wire electrical discharge machining is used for forming the channels with different inclination angles and the sinking electrical discharge machining is used for forming dimples with different sizes.…”

Section: Methods Of Creating Texturingmentioning

confidence: 99%

“… Nano-textured increased the performance by decreasing the cutting temperature and friction coefficient. Areal texture shows best results in comparison with others [ 40 ] Linear band parallel to the main cutting edge Areal texture EDM Microgrinding tool Design a correlation between the different machining parameters and textures Channels Large numbers of texture with small size units are better than low number units and big size texture in reducing cutting force and resulted in surface roughness [ 46 ] Plasma-assisted laser machining Cemented carbide tool Support of PVD coating adhesion Linear texturing The coating adhesiveness of the plasma texturing was enhanced in comparison with untextured surface [ 38 ] Wire electrical discharge machining Al 2 O 3 /TiCN ceramic cutting tool Decreasing the chip-contact length for increasing tool life and performance Linear texture at angle to chip flow. Texture of first and second type restrict the chip flow length, hence the friction was decreased.…”

Section: Table A1mentioning

confidence: 99%

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The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review

et al. 2022

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Machining is an indispensable manufacturing process for a wide range of engineering materials, such as metals, ceramics, and composite materials, in which the tool wear is a serious problem, which affects not only the costs and productivity but also the quality of the machined components. Thus, the modification of the cutting tool surface by application of textures on their surfaces is proposed as a very promising method for improving tool life. Surface texturing is a relatively new surface engineering technology, where microscale or nanoscale surface textures are generated on the cutting tool through a variety of techniques in order to improve tribological properties of cutting tool surfaces by reducing the coefficient of friction and increasing wear resistance. In this paper, the studies carried out to date on the texturing of ceramic and superhard cutting tools have been reviewed. Furthermore, the most common methods for creating textures on the surfaces of different materials have been summarized. Moreover, the parameters that are generally used in surface texturing, which should be indicated in all future studies of textured cutting tools in order to have a better understanding of its effects in the cutting process, are described. In addition, this paper proposes a way in which to classify the texture surfaces used in the cutting tools according to their geometric parameters. This paper highlights the effect of ceramic and superhard textured cutting tools in improving the machining performance of difficult-to-cut materials, such as coefficient of friction, tool wear, cutting forces, cutting temperature, and machined workpiece roughness. Finally, a conclusion of the analyzed papers is given.

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Section: Methods Of Creating Texturingmentioning

confidence: 99%

Section: Table A1mentioning

confidence: 99%

The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review

et al. 2022

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“…where ε is a unitless constant (ε = 0.15) [28,29], Hp is the material hardness, Ep is Young's modulus, and KIC tensile strength. As shown in Figure 2b, the entire process of the surface grinding on the interactivity between the grits and the workpiece is classified as ductile region, ductile-brittle transition, and brittle region.…”

Section: Chip Thickness Of the Ductile-brittle Transitionmentioning

confidence: 99%

“…where ε is a unitless constant (ε = 0.15) [28,29], H p is the material hardness, E p is Young's modulus, and K IC tensile strength.…”

Section: Chip Thickness Of the Ductile-brittle Transitionmentioning

confidence: 99%

Model for Predicting the Micro-Grinding Force of K9 Glass Based on Material Removal Mechanisms

et al. 2020

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K9 optical glass has superb material properties used for various industrial applications. However, the high hardness and low fracture toughness greatly fluctuate the cutting force generated during the grinding process, which are the main factors affecting machining accuracy and surface integrity. With a view to further understand the grinding mechanism of K9 glass and improve the machining quality, a new arithmetical force model and parameter optimization for grinding the K9 glass are introduced in this study. Originally, the grinding force components and the grinding path were analyzed according to the critical depth of plowing, rubbing, and brittle tear. Thereafter, the arithmetical model of grinding force was established based on the geometrical model of a single abrasive grain, taking into account the random distribution of grinding grains, and this fact was considered when establishing the number of active grains participating in cutting Nd-Tot. It should be noted that the tool diameter changed with machining, therefore this change was taking into account when building the arithmetical force model during processing as well as the variable value of the maximum chip thickness amax accordingly. Besides, the force analysis recommends how to control the processing parameters to achieve high surface and subsurface quality. Finally, the force model was evaluated by comparing theoretical results with experimental ones. The experimental values of surface grinding forces are in good conformity with the predicted results with changes in the grinding parameters, which proves that the mathematical model is reliable.

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“…In order to change tribological characteristics, Siju et al [10] also fabricated innovative dual-texture geometries on the tool. Ashwani et al [11] created tools with an optimal intermittent ratio and varying texture dimensions. Although textures can improve tool-cutting performance, they also destroy the stress distribution on the tool surface and reduce tool strength.…”

Section: Introductionmentioning

confidence: 99%

Assessment of a Bionic Broach Implanted with Nylon Fibers

Zhang

Feng

et al. 2022

Materials

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The optimization of a broach surface is of great significance to improve the cutting performance of the tool. However, the traditional optimization method (surface texture, coating, etc.) destroys the stress distribution of the tool and reduces the service life of the tool. To avoid these problems, four kinds of flocking surfaces (FB1, FB2, FB3, and FB4), imitating the biological structure of Daphniphyllum calycinum Benth (DCB), were fabricated on the rake face of the broach by electrostatic flocking. The broaching experiment, wettability, and spreading experiment were then conducted. Moreover, the mathematical model of the friction coefficient of the bionic broach was built. The effect of broaches with different flocking surfaces on the broaching force, chip morphology, and surface quality of workpieces was studied. The results indicate that the flocked broaches (FB) with good lubricity and capacity of microchips removal (CMR) present a smaller cutting force (Fc) and positive pressure (Ft) compared to the unflocked broach (NB), and reduce the friction coefficient (COF). The chip curl was decreased, and the shear angle was increased by FB, which were attributed to the function of absorbing lubricant, storing, and sweeping microchips. Its vibration suppression effect enhanced the stability in the broaching process and improved the surface quality of the workpiece. More importantly, the FB2 with the most reasonable fluff area and spacing exhibited the best cutting performance. The experimental conclusions and methods of this paper can provide a new research idea for functional structure tools.

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Combined effects of tool surface texturing, cutting parameters and minimum quantity lubrication (MQL) pressure on micro-grinding of BK7 glass

Cited by 32 publications

References 28 publications

The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review

The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review

Model for Predicting the Micro-Grinding Force of K9 Glass Based on Material Removal Mechanisms

Assessment of a Bionic Broach Implanted with Nylon Fibers

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