Investigation on the use of cutting temperature and tool wear in the turning of mild steel bars

Abstract

The paper is concerned with the development of a data acquisition system for the measurement of temperature used for metal cutting. In this study, machining tests were performed and an analysis of the temperature and wear of the cutting tool is presented herein. In metal cutting operations, the wear of tools is generated largely due to the heat emitted from the cutting zone. Therefore, a coolant is often used to cool down the cutting area and protect the cutting tools. However, because of environmental concerns, engineers now try to avoid using cutting coolants and perform cutting operations in almost dry conditions. In this study, a mild-steel round bar was turned at various feed rates, depths of cut and cutting speeds. A data acquisition system was built to record the cutting temperature while turning the bar. From the study, it is evident that certain combinations of cutting parameters result in higher temperatures than those produced in other experiments. It was established that the depth of cut and cutting speed at their highest values (1 mm and 250 m/min, respectively) contribute largely to the high surface temperature, while the effect of feed rate is intangible. Increasing the cutting speed results in an increase in the cutting temperature. A similar result was observed when the depth of cut was increased. However, increases in feed rate did not significantly cause increases in cutting temperature. In addition, cutting inserts were examined under a scanning electron microscope (SEM) to quantify the tool wear in each experiment. A correlation between tool wear and temperature is clearly noticed. The study concluded that the combination of variations in cutting speed and depth of cut results in severe tool wear action on the tool's flank face as a result of the intensive heat generated.

Optimization of Machining Parameters Using Fuzzy Taguchi Method for Reducing Tool Wear

“…It was found that tool life can be estimated and the production cost can be reduced by using image recognition software and artificial neural network (ANN). The Taguchi Method was also employed to select cutting parameters (tool nose radius, cutting speed, feed rate, and cutting depth) An experimental study [4] in turning mild-steel round bar by using various combinations of federate, cutting depth, and speed was also developed. Through the scanning electron microscope (SEM), the tool wear can be measured.…”

Analysis and prediction of residual stresses based on cutting temperature and cutting force in rough turning of Ti–6Al–4V

“…(2020) established a mathematical model between cutting parameters and cutting force through multiple regression analysis. Abou-El-Hossein and Kops (2017) explored the influences of cutting parameters on cutting temperature, showing that excessive depth of cut and cutting speed led to high cutting temperatures, which adversely affected tool life. Ţîțu et al.…”

Parameter Optimization for Computer Numerical Controlled Machining Using Fuzzy and Game Theory

“…Hossein and Kops's research showed that the cutting temperature increases under larger cutting depth and higher cutting speed, which in turn shortens the tool life. However, the research took time to carry out the cutting work and belonged solely to the research of a single quality and not a multi-quality research [5]. The research of Schultheiss et al which pointed out that reducing the tool wear can shorten the time of the production cycle and reduce energy consumption, was also a single quality research and not a multi-quality research [6].…”