Comparative assessment of coated and uncoated ceramic tools on cutting force components and tool wear in hard turning of AISI H11 steel using Taguchi plan and RMS

Aouici, Hamdi; Khellaf, A.; Smaiah, S.; Elbah, M.; Fnides, B.; Yallese, Mohamed Athmane

doi:10.1007/s12046-017-0746-1

Cited by 12 publications

(3 citation statements)

References 26 publications

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“…The typical 3 D surface plot shown in Figure 9(a) illustrates the impact of two cutting variables (cutting speed and axial feed) on surface roughness (Ra). Surface roughness decreased with the rise in cutting speed possibly due to elimination of BUE formation and material side flow, 45 leading to improved surface quality as the influence of tool wear was neglected. Figure 10 shows the SEM micrograph of hard turned component having poor surface quality that explains the various topographical status.…”

Section: Resultsmentioning

confidence: 99%

Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

Dash

Padhan

Das³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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The present research addresses the machinability of hardened die steel (AISI D3, 61HRC) in hard turning using multilayer (TiCN/Al2O3/TiN) coated carbide tool under nanofluid based minimum quantity lubrication-cooling condition, where no previous data are available. Power consumption, flank wear, chip morphology and surface integrity (microhardness, residual stress, white layer formation, machined surface morphology, and surface roughness) are considered as technological performance characteristics to evaluate the machinability. Combined approach of central composite design - analysis of variance, response surface methodology and desirability function analysis have been employed respectively for experimental investigation, predictive modelling and multi-response optimization. With a motivational philosophy of “Go Green-Think Green-Act Green”, the work also deals with energy saving carbon footprint analysis and sustainability assessment to recognize the green manufacturing in the context of safer and cleaner production. under environmental-friendly nanofluid assisted minimum quantity lubrication condition. The quantitative analysis revealed that the cutting speed influenced the power consumption during hard machining (75.78%) and flank wear of coated carbide tool (45.67%); feed rate impacted the surface finish of the machined part (68.8%) significantly. Saw tooth shapes of chip produced due to cyclic cracking. Due to low percentage contribution of error (5.32% to Ra, 6.64% to VB, and 7.79% to Pc), a higher correlation coefficient (R2) was obtained with the quadratic regression model, which showed values of 0.9, 0.88 and 0.92 for surface roughness, flank wear, and power consumption, respectively. Optimization with the highest desirability (0.9173) resulted the optimum machining conditions under NFMQL at the cutting speed of 57 m/min, depth of cut 0.1 mm, feed of 0.07 mm/rev, and insert’s nose radius of 0.4 mm. As a result, under NFMQL tool life was improved by 30.8% and 22.6% in respect of flank wear and surface roughness respectively than when machining with MQL technique by adapting the optimum machining condition. Therefore, using hard nanoparticles-reinforced cutting fluid under minimum quantity lubrication condition in practical manufacturing becomes very promising to improve sustainability.

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Section: Resultsmentioning

confidence: 99%

Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

Dash

Padhan

Das³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…The solution treated sample shows 240 HV of micro-hardness, cryogenic treated sample shows 283 HV micro-hardness and heat treated samples shows higher microhardness of 390 HV, respectively. This material is introduced for other machinability studies in the upcoming sections to know its further machinability and tool wear performance [15]. The experimental machining conditions are given in Table 1.…”

Section: Resultsmentioning

confidence: 99%

Multi Objective Study on Machining Characteristics of AISI H-11 Tool Steel Prepared by Different Processing Techniques

Margabandu¹,

Ramanujam²

2021

JESA

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In the current study, hard turning of AISI H11 tool steel is done using TiAlN coated cutting tool. The workpiece is prepared by three different processing conditions (Solution treated, Heat treated, Cryogenic treated). The machining performance are studied by the input parameters; cutting speed (60, 90, 120 m/min) and feed rate (0.06, 0.12, 0.18 mm/rev) with a constant depth of cut of 0.5mm using Taguchi’s L9 design. The responses like, surface quality, wear on the tool, and forces generated for all three specimens are studied. The hardness of all three components is measured using Vicker’s micro-hardness tester. The experimental results proved that feed rate is the most influential parameter in deciding, surface roughness, cutting force and tool wear. The utility concept approach is applied and found, solution treated sample with 120 m/min of cutting speed and 0.06 mm/rev of feed rate produces optimal results in all three response criterion.

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“…A rational choice of WEDM modes is extremely important to ensure the dimensional quality of the manufactured cutting inserts [37][38][39], while roughness of the machined surface on the cutting edge is of great importance with regards to the application of wear-resistant coatings [40][41][42][43][44], which increases tool life [45][46][47][48][49][50][51][52][53][54][55][56][57]. During uniform charge distribution, only the side of the electrode facing the workpiece is heating up, whereas when the discharges are localized [58,59], the wire is heating up to the full depth [60].…”

Section: Introductionmentioning

confidence: 99%

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

Grigoriev

Pivkin

Kozochkin

et al. 2021

Metals

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The field of applied wire electrical discharge machining (WEDM) is rapidly expanding due to rapidly increasing demand for parts made of hard-to-machine materials. Hard alloys composed of WC, TiC and Co are advanced cutting materials widely used in industry due to the excellent combination of hardness and toughness, providing them obvious advantages over other cutting materials, such as cubic boron nitride, ceramics, diamond or high-speed steel. A rational choice of the WEDM modes is extremely important to ensure the dimensional quality of the manufactured cutting inserts, while roughness of the machined surface on the cutting edge is of great importance with regards to the application of wear-resistant coatings, which increases tool life. However, the stock control systems of CNC WEDM machines, which are based on assessment of electrical parameters such as amperage and voltage, are unable to timely detect conditions at which a threat of wire breakage appears and to prevent wire breakage by stopping the electrode feed and flushing out the interelectrode gap (IEG) when hard alloys with high heat resistance and low heat conductivity, such as WC, TiC and Co composites, are being machined, due to the inability to distinguish the working pulses and pulses that expend a part of their energy heating and removing electroerosion products contaminating the working zone. In this paper, the physicomechanical nature of the WEDM of hard alloy WC 88% + TiC 6% + Co 6% was investigated, and the possibility of using acoustic emission parameters for controlling WEDM stability and productivity were explored. Acoustic emission (AE) signals were recorded in octave bands with central frequencies of 1–3 and 10–20 kHz. It was found that at the initial moment, when the dielectric fluid is virtually free of contaminants, the amplitude of the high-frequency component of the VA signal has its highest value. However, as the contamination of the working zone by electroerosion products increases, the amplitude of the high-frequency component of the AE signal decreases while the low-frequency component increases in an octave of 1–3 kHz. By the time of the wire breakage, the amplitude of the high-frequency component in the octave of 10–20 kHz had reduced by more than 5-fold, the amplitude of the low-frequency component in the octave of 1–3 kHz had increased by more than 2-fold, and their ratio, coefficient Kf, decreased by 12-fold. To evaluate the efficiency of Kf as a diagnostic parameter, the quality of the surface being machined was investigated. The analysis of residual irregularities on the surface at the electrode breakage point showed the presence of deep cracks and craters typical of short-circuit machining. It was also found that the workpiece surface was full of deposits/sticks, whose chemical composition was identical to that of the wire material. The presence of the deposits evidenced heating and melting of the wire due to the increased concentration of contaminants causing short circuits. It was also shown that the wire breakage was accompanied by the “neck” formation, which indicated simultaneous impacts of the local heating of the wire material and tensile forces. Due to the elevated temperature, the mechanical properties the wire material are quickly declining, a “neck” is being formed, and, finally, the wire breaks. At the wire breakage point, sticks/deposits of the workpiece material and electroerosion products were clearly visible, which evidenced a partial loss of the pulses’ energy on heating the electroerosion products and electrodes. A further increase in the contamination level led to short circuits and subsequent breakage of the wire electrode. It was shown that in contrast to the conventional controlling scheme, which is based on the assessment of amperage and voltage only, the analysis of VA signals clearly indicates the risk of wire breakage due to contamination of the working zone, discharge localization and subsequent short circuits. The monotonic dependence of WEDM productivity on AE parameters provides the possibility of adaptive adjustment of the wire electrode feed rate to the highest WEDM productivity at a given contamination level. As the concentration of contaminants increases, the feed rate of the wire electrode should decrease until the critical value of the diagnostic parameter Kf, at which the feed stops and the IEG flushes out, is reached. The link between the AE signals and physicomechanical nature of the WEDM of advanced cutting materials with high heat resistance and low heat conductivity in different cutting modes clearly shows that the monitoring of AE signals can be used as a main or supplementary component of control systems for CNC WEDM machines.

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Comparative assessment of coated and uncoated ceramic tools on cutting force components and tool wear in hard turning of AISI H11 steel using Taguchi plan and RMS

Cited by 12 publications

References 26 publications

Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

Multi Objective Study on Machining Characteristics of AISI H-11 Tool Steel Prepared by Different Processing Techniques

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

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