Machining hardmetal with CVD diamond direct coated ceramic tools: effect of tool edge geometry

Almeida, F.A.; Oliveira, F.J.; Sousa, Maria P.; Fernandes, A.J.S.; Sacramento, J.; Silva, Rui

doi:10.1016/j.diamond.2004.09.002

Cited by 38 publications

(20 citation statements)

References 12 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The smallest machined surface roughness was observed in the case when the value of machining force F c was below 35 N. However, in the work, the impact of a cutting edge shape on machining process was not included. The work of Almeida et al [17] can be complementary to these studies, in which the influence of the cutting edge shape (sharp, honed, and chamfered) of round cutting tool inserts made via direct diamond deposition on Si 3 N 4 ceramic substrate on the cutting force value while turning of WC-Co containing 25 wt% Co was analyzed. The smallest machining force values and the best work piece finishing quality (Ra<0.2 μm) were registered for tools with the sharp edge tools.…”

Section: Introductionmentioning

confidence: 85%

“…(7) and (9) for the first model type should be used. Figures 15,16,17, and 18 present the examples of diagrams according to the mathematical equations describing the first type of experimental model. The cutting force F c in the function of the depth of cut a p and cutting speed v c for the first shaft are shown in Fig.…”

Section: First Type Of Experimental Model Based On the Power Functionmentioning

confidence: 99%

See 1 more Smart Citation

Estimating the effect of cutting data on surface roughness and cutting force during WC-Co turning with PCD tool using Taguchi design and ANOVA analysis

Zębala

Kowalczyk

2014

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The cutting of high hardness composite materials such as sintered carbides based on the cobalt is a challenge from a technological point of view. The paper presents the influence of cutting data (v c , f, a p ) and cobalt content in a work piece (10, 15, and 25 wt%) on the turning process of WC-Co with polycrystalline diamond (PCD) tool. This study focuses on the main component of cutting force F c and surface roughness, described by the roughness parameter Ra. The research plan, based on the Taguchi method, and variance analysis ANOVA were applied. Two types of experimental model, which describes turning process of sintered carbides based on the power function for three variables and polynomial functions as a modified method of the response surface methodology (RSM), were also presented.

show abstract

Section: Introductionmentioning

confidence: 85%

Section: First Type Of Experimental Model Based On the Power Functionmentioning

confidence: 99%

Estimating the effect of cutting data on surface roughness and cutting force during WC-Co turning with PCD tool using Taguchi design and ANOVA analysis

Zębala

Kowalczyk

2014

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…Increase in productivity together with good finish can be achieved with these tools, if only the last pass of the cutting is made at these conditions. The cutting forces developed in hard metal turning with CVD diamond tools increase with the bluntness of the cutting edge in the following order: sharp< chamfer< hone [26]. During the orthogonal turning of AISI 4340 steel, waterfall-hone (ovallike edge) tools yielded lower forces than honed and chamfered tools.…”

Section: Tool Edge (Curvilinear Edge/ Wiper Geometry)mentioning

confidence: 99%

Untitled

2011

JESTR

View full text Add to dashboard Cite

The effect of cutting tool geometry has long been an issue in understanding mechanics of turning. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning. This article presents a survey on variation in tool geometry i.e. tool nose radius, rake angle, groove on the rake face, variable edge geometry, wiper geometry and curvilinear edge tools and their effect on tool wear, surface roughness and surface integrity of the machined surface. Further modeling and simulation approaches on tool geometry including one approach developed in a recent study, on variable micro-geometry tools, is discussed in brief.Keywords: Curvilinear edge, rake angle, grooved tools, nose radius, variable geometry. Stringent control on the quality of machined surface and sub-surface during turning is most important consideration a part from considering the tool life. In order to attain sufficiently high production rates at minimum cost, optimization of cutting tool geometry is necessary [1], [2]. The design of cutting edge geometry and its influence on machining performance have been a research topic in metal cutting for a long time. Edge preparation has a critical effect on the tool life. A tool with poor edge preparation may chip and fail quickly [3]. Users expect to have more and more productivity in their machining processes (high removal rate of work-material) and low wear of their cutting tools (long tool life). These demands require major improvements in the design of cutting tools: new substrates, new coatings, cutting tool geometry and materials etc. According to tool manufacturers, the manufacturing procedures of their cutting tools, especially the micro-geometry preparation (cutting edge etc.), have a major influence on their performance and on their reliability [4]. Edge preparation must be carefully selected for a given application because it affects the surface integrity of the machined workpiece (white layer, residual stresses etc.) [5]. Heat generated during hard turning is also affected by edge preparation due to change in work material flow around the cutting edge. For example, a chamfered face provides excessive negative angle to the cutting action and results in high heat generation. PCBN tools rapidly wear out during hard turning at high cutting speeds mainly due to attained temperatures [6].It is important to consider the tool-edge effect in order to better understand the chip formation mechanism and accurately predict machining performances, such as cutting forces, cutting temperatures, tool wear, surface finish and the machined surface integrity. The methods commonly employed include experimental, analytical, and numerical methods [7]. The tool geometry effects on turning performance parameters are mentioned in Figure1.It is demonstrated that the cutting tool edge geometry significantly influences many fundamental aspects such as cutting forces, chip formation, cutting temperature, tool wear, tool-life and characteristics like sur...

show abstract

“…8 A schematic view of the insert during cutting can be seen in Figure 1. A 3-component measuring system for cutting force evaluation during turning (Kistler type 9129AA, Winterthur, Switzerland) was coupled to the lathe.…”

Section: Tool Angles and Corner Radius Valuementioning

confidence: 99%

Multilayer CVD Diamond Coatings in the Machining of an Al6061-15 Vol % Al2O3 Composite

et al. 2017

View full text Add to dashboard Cite

Abstract:Ceramic cutting inserts coated with ten-fold alternating micro-and nanocrystalline diamond (MCD/NCD) layers grown by hot filament chemical vapor deposition (CVD) were tested in the machining of an Al based metallic matrix composite (MMC) containing 15 vol % Al 2 O 3 particles. Inserts with total coating thicknesses of approximately 12 µm and 24 µm were produced and used in turning: cutting speed (v) of 250 to 1000 m·min −1 ; depth of cut (DOC) from 0.5 to 3 mm and feed (f ) between 0.1 and 0.4 mm·rev −1 . The main cutting force increases linearly with DOC (ca. 294 N per mm) and with feed (ca. 640 N per mm·rev −1 ). The thicker coatings work within the following limits: DOC up to 1.5 mm and maximum speeds of 750 m·min −1 for feeds up to 0.4 mm·rev −1 . Flank wear is predominant but crater wear is also observed due to the negative tool normal rake. Layer-by-layer wear of the tool rake, and not total delamination from the substrate, evidenced one of the advantages of using a multilayer design. The MCD/NCD multilayer diamond coated indexable inserts have longer tool life than most CVD diamond systems and behave as well as most polycrystalline diamond (PCD) tools.

show abstract

Machining hardmetal with CVD diamond direct coated ceramic tools: effect of tool edge geometry

Cited by 38 publications

References 12 publications

Estimating the effect of cutting data on surface roughness and cutting force during WC-Co turning with PCD tool using Taguchi design and ANOVA analysis

Estimating the effect of cutting data on surface roughness and cutting force during WC-Co turning with PCD tool using Taguchi design and ANOVA analysis

Untitled

Multilayer CVD Diamond Coatings in the Machining of an Al6061-15 Vol % Al2O3 Composite

Contact Info

Product

Resources

About