Impact Resistance of PVD Films and Milling Performance of Coated Tools at Various Temperature Levels

Bouzakis, K.‐D.; Mirisidis, I.; Lili, E.; Michailidis, Nikolaos; Sampris, Anastasios; Skordaris, G.; Pavlidou, E.; Erkens, G.; Wirth, Ingo

doi:10.1016/s0007-8506(07)60368-0

Cited by 23 publications

(17 citation statements)

References 5 publications

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“…Many efforts have been made in describing, through analytical models, the various wear mechanisms as function of process parameters [4][5][6], tool material and geometry and workpiece material [1,2]. In contrast, only few regard the simulation of tool wear [7,8] especially when 3D simulation is used [9] and within these, the utilized tool wear models were focused on some of the main wear mechanisms only. From a theoretical point of view, this assumption can be done when the implemented tool wear mechanism results very predominant respect to the other ones.…”

Section: Introductionmentioning

confidence: 99%

Abrasive and diffusive tool wear FEM simulation

Attanasio

Umbrello

2009

Int J Mater Form

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In this paper, an adopted abrasive-diffusive wear model is proposed and implemented into a 3D Finite Element code to study the tool wear phenomenon. In particular, the Authors found that FE procedure based only on diffusive mechanism shown some problems when the extension on crater area was investigated. This can be related to the absence of the wear abrasion term on the utilized model. Therefore, in this work, the Authors improved the previous utilized tool wear model introducing into the sub-routine the abrasive term on the basis of Usui’s model. A series of 3D FEM simulations were conducted in order to estimate the tool wear development in turning operations. The adopted abrasive-diffusive wear model will give the possibility of correctly evaluating the tool wear of actual turning operations during both the initial transient phase, where the abrasive mechanism is dominant, and the steady-state phase, in which the diffusion is the main wear mechanism. The FEM results were compared with experimental data, obtained turning AISI 1045 steel with WIDIA P40 inserts, showing a satisfactory agreement

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Section: Introductionmentioning

confidence: 99%

Abrasive and diffusive tool wear FEM simulation

Attanasio

Umbrello

2009

Int J Mater Form

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“…3. These stress fields were calculated using the ANSYS software package, taking into account the load distributions and the mechanical properties of the films and the substrate [3,13]. The films' intrinsic stress is already included in the information given by the stress-strain curve [16,17].…”

Section: The Effect Of Chip Thicknessmentioning

confidence: 99%

“…The PVD films' strength properties at room and elevated temperatures were detected through impact test investigations [3,13,14]. These results, along with FEM-based calculations of the cutting wedge thermal and mechanical loads during the material removal process, facilitated the explanation of the coated inserts' cutting performance at various conditions.…”

Section: Introductionmentioning

confidence: 99%

Correlation of the impact resistance of variously doped CrAlN PVD coatings with their cutting performance in milling aerospace alloys

Bouzakis

Michailidis

Gerardis

et al. 2008

Surface and Coatings Technology

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“…Yen et al [5] evaluated wear with the parameters of metal cutting tools (e.g., cutting temperature, contact stress and relative sliding speed), indicating that such parameters play major roles in tool wear. Dubar et al [6], Bouzakis et al [7] and Filice et al [8] also analyzed wear in coated cutting tools. Stavropoulos et al [9] investigated the limitations of tool wear prediction on the milling of CGI 450 plates through the simultaneous detection of acceleration and spindle drive current sensor signals.…”

Section: Introductionmentioning

confidence: 99%

Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts

Hsia

Shih²

2015

Materials

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Cold forging has played a critical role in fasteners and has been widely used in automotive production, manufacturing, aviation and 3C (Computer, Communication, and Consumer electronics). Despite its extensive use in fastener forming and die design, operator experience and trial and error make it subjective and unreliable owing to the difficulty of controlling the development schedule. This study used finite element analysis to establish and simulate wear in automotive repair fastener manufacturing dies based on actual process conditions. The places on a die that wore most quickly were forecast, with the stress levels obtained being substituted into the Archard equation to calculate die wear. A 19.87% improvement in wear optimization occurred by applying the Taguchi quality method to the new design. Additionally, a comparison of actual manufacturing data to simulations revealed a nut forging size error within 2%, thereby demonstrating the accuracy of this theoretical analysis. Finally, SEM micrographs of the worn surfaces on the upper punch indicate that the primary wear mechanism on the cold forging die for long hex flange nuts was adhesive wear. The results can simplify the development schedule, reduce the number of trials and further enhance production quality and die life.

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Impact Resistance of PVD Films and Milling Performance of Coated Tools at Various Temperature Levels

Cited by 23 publications

References 5 publications

Abrasive and diffusive tool wear FEM simulation

Abrasive and diffusive tool wear FEM simulation

Correlation of the impact resistance of variously doped CrAlN PVD coatings with their cutting performance in milling aerospace alloys

Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts

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