Effect of the Cutting Edge Radius and its Manufacturing Procedure, on the Milling Performance of PVD Coated Cemented Carbide Inserts

Bouzakis, K.‐D.; Michailidis, Nikolaos; Skordaris, G.; Kombogiannis, S.; Hadjiyiannis, S.; Efstathiou, Kyriakos; Erkens, G.; Rambadt, S.; Wirth, Ingo

doi:10.1016/s0007-8506(07)61466-8

Cited by 48 publications

(17 citation statements)

References 8 publications

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“…Generally, this procedure is applied to coatings to clean, smooth the surface and reduce sharp cutting edges [14][15][16]. This process involves the use of high pressure and abrasive powders.…”

Section: Introductionmentioning

confidence: 99%

Influence of micro-blasting on the microstructure and residual stresses of CVD κ-Al2O3 coatings

Barbatti

García

Pitonak³

et al. 2009

Surface and Coatings Technology

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Cemented carbides coated with CVD multilayers are commonly used in metal cutting turning and milling operations. For many applications, a micro-blasting finishing procedure based on an impact treatment of the surfaces is carried out in order to smooth the coated surface and reduce sharp cutting edges. In this work, micro-blasting with corundum in aqueous solution at pressures between 0.05 and 0.3 MPa was applied to CVD TiN/Ti(C,N)/κ-Al 2 O 3 multilayer coatings deposited onto cemented carbides in order to investigate its influence on the micro-topography, microstructure and residual stresses. The results showed that the microblasting reduces the surface roughness and affects the coating thickness. TEM investigations revealed no significant changes on the microstructure of the κ-Al 2 O 3 top layer. Synchrotron X-ray investigations showed that the residual stress state of the as-deposited κ-Al 2 O 3 top layer is not affected by the micro-blasting treatment under the conditions investigated.

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Section: Introductionmentioning

confidence: 99%

Influence of micro-blasting on the microstructure and residual stresses of CVD κ-Al2O3 coatings

Barbatti

García

Pitonak³

et al. 2009

Surface and Coatings Technology

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“…In the past, there were many studies analyzing the influence of different characteristic values according the tool life and wear behavior. Research was done with carbide tools [22,18,23,13,14,11,24] as well as high speed steel hobs (PM-HSS) [19,1,7,16,15,17,21]. HOFFMEISTER [18] developed an approximation formula for the maximum cutting length l max and total cutting length l of the process.…”

Section: Characteristic Values In Gear Hobbingmentioning

confidence: 99%

“…BOUZAKIS [1] conducted extensive research regarding the chip formation and the effects to tool wear. For this, BOUZAKIS classified the three flank chips and developed a mathematical model for calculating the corresponding tool wear.…”

Section: Characteristic Values In Gear Hobbingmentioning

confidence: 99%

Design of Gear Hobbing Processes Using Simulations and Empirical Data

Brecher¹,

Brumm²,

Krömer³

2015

Procedia CIRP

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Gear Hobbing is one of the most productive manufacturing processes for pre-machining cylindrical gears. The process design as well as the tool selection is often based on experience or is limited to an iterative procedure. Existing methods for process and tool design are limited regarding the size of the gears and the process parameters.The objective presented in this paper is to support the process design by suggesting process parameters. To achieve this goal, a simulation for continuous gear hobbing was developed. By calculating planar intersections of transverse sections of both gear and tool, the generated chip geometries are determined. Due to the general approach of positioning tool and workpiece in the program, all continuous processes with defined cutting edges can be simulated. The generated chip geometries are analyzed and characteristic values for each position of the tool are defined. Beside the chip geometries, other parameters such as working areas and the length of axis movements are calculated too.Since the simulation process is time-consuming, it is not possible to calculate each hobbing process for different designs. Also, the simulation program cannot be implemented into the machine control due to the needed computing capacity. Thus, a large amount of hobbing processes with varying gear geometries as well as different tools with the corresponding profiles are calculated in advance. By the use of regression analysis, the results of these variations are transferred to approximation formulas afterwards, which are easy to calculate and to implement into other software products.To support the tool and process design, existing hobbing processes will be simulated with the help of the developed manufacturing simulation and the results will be stored in a database. By comparing the results of the approximation formulas with the values in the database, it is possible to evaluate a given process.

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“…The advancement of the coating technology leads to the fact that in particular the market share of new improved and also complex coatings will strongly increase in the coming years. Special attention, however, must be given to the cutting edge radius, which is dependent on the coating thickness [26]. A thin coating thickness, leads to strongly negative face angles.…”

Section: Cutting Tool Manufacturementioning

confidence: 99%

Advancing Cutting Technology

Byrne

Dornfeld

Denkena³

2003

CIRP Annals

581

199

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This paper reviews some of the main developments in cutting technology since the foundation of CIRP over fifty years ago. Material removal processes can take place at considerably higher performance levels in the range up to Q w = 150 -1500 cm 3 /min for most workpiece materials at cutting speeds up to some 8.000 m/min. Dry or near dry cutting is finding widespread application. The superhard cutting tool materials embody hardness levels in the range 3000 -9000 HV with toughness levels exceeding 1000 MPa. Coated tool materials offer the opportunity to fine tune the cutting tool to the material being machined. Machining accuracies down to 10 µm can now be achieved for conventional cutting processes with CNC machine tools, whilst ultraprecision cutting can operate in the range < 0.1µm. The main technological developments associated with the cutting tool and tool materials, the workpiece materials, the machine tool, the process conditions and the manufacturing environment which have led to this advancement are given detailed consideration in this paper. The basis for a roadmap of future development of cutting technology is provided.

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Effect of the Cutting Edge Radius and its Manufacturing Procedure, on the Milling Performance of PVD Coated Cemented Carbide Inserts

Cited by 48 publications

References 8 publications

Influence of micro-blasting on the microstructure and residual stresses of CVD κ-Al2O3 coatings

Influence of micro-blasting on the microstructure and residual stresses of CVD κ-Al2O3 coatings

Design of Gear Hobbing Processes Using Simulations and Empirical Data

Advancing Cutting Technology

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