Tool wear analysis of ceramic cutting tools in the turning of gray cast iron materials

Lubis, Sobron; Darmawan, Steven; Rosehan,; Winata, William; Zulkarnain, M.; Mimet, UniKL

doi:10.1088/1757-899x/857/1/012003

Cited by 2 publications

(2 citation statements)

References 3 publications

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“…Coolant supply can help enhance the tool life when using metallic cutting tools. However, this is not observed when using ceramic tools, which perform better under dry machining conditions [ 11 , 17 ]. To provide an alternative heat transfer method to the use of external coolants for cutting inserts, an integrated internal cooling system is well suited for ceramic materials.…”

Section: Introductionmentioning

confidence: 99%

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamber of the cutting tool. In this context, this paper proposes an alternative method in which liquid gallium is used as the coolant in combination with a magnetohydrodynamic (MHD) pump, which avoids the need for an external power source. Using computational fluid dynamics, we created a numerical model of an internal cooling system and then solved it under conditions in which a magnetic field was applied to the liquid metal. This was followed by a simulation study performed to evaluate the effectiveness of liquid gallium over liquid water. The results of experiments conducted under non-cooling and liquid gallium cooling conditions were analyzed and compared in terms of the tool wear rate. The results showed that after six machining cycles at a cutting speed Vc = 250 m min −1, the corner wear VBc rate was 75 µm with the coolant off and 48 µm with the MHD-based coolant on, representing a decrease of 36% in tool wear. At Vc = 900 m min−1, the corner wear VBc rate was 75 µm with the coolant off and 246 µm with the MHD-based coolant on, representing a decrease of 31% in tool wear. When external cooling using liquid water was added, the results showed at Vc = 250 m min−1, the difference between the tool wear rate reduction with the internal liquid gallium coolant relative to the external coolant was 29%. When the cutting speed was increased to Vc = 900 m min−1, the difference observed between the internal liquid gallium coolant relative to the external coolant was 16%. The study proves the feasibility of using liquid gallium as a coolant to effectively remove thermal energy through internally fabricated cooling channels in cutting inserts.

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Section: Introductionmentioning

confidence: 99%

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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“…However, the connection between the acoustic emission waveform obtained and the acoustic emission source mechanism must be understood while using this method, otherwise the physical nature of the acoustic emission waveform cannot be found. Although the application of time series analysis in some cases have achieved some results, this method cannot explain the reason of calculating the auto-regressive coefficient and three catting pick factors as input variables of a neural network (Lubis et al, 2020;Ma et al, 2020). Fourier transformation embodies information of the signal in the frequency domain and does not change with time.…”

Section: Introductionmentioning

confidence: 99%

Recognition of pick wear condition based on Grey-Markov chain model

Zhang¹,

Zhang²

2023

Journal of Theoretical and Applied Mechanics

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An attempt is made in this paper to solve the pick wear problem of mining machinery and propose a pick wear degradation model based on the Grey-Markov chain by using generated characteristics signals and certain pick wear parameters to enhance the prediction accuracy. The vibration and acoustic emission signals generated during the catting pick are extracted and analyzed. The energy and the value of the characteristic signal are obtained by wavelet analysis to construct a characteristic sample library of the signals. Two kinds of signals are applied to the model to analyze the error between the real and the predicted values. The model prediction results demonstrate a 1.43% error of the vibration signal, 1.64% error of the acoustic emission signal with 98% prediction accuracy, thus offers a new method for monitoring the pick wear of mining machinery.

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Tool wear analysis of ceramic cutting tools in the turning of gray cast iron materials

Cited by 2 publications

References 3 publications

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Recognition of pick wear condition based on Grey-Markov chain model

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