Tool wear and surface roughness analysis in milling with ceramic tools of Waspaloy: a comparison of machining performance with different cooling methods

Yıldırım, Çağrı Vakkas; Kıvak, Turgay; Erzincanlı, Fehmi

doi:10.1007/s40430-019-1582-5

Cited by 70 publications

(33 citation statements)

References 23 publications

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“…Lopes-da Silva and Hassui [27] studied the effects of tool path along with the process parameters on cutting forces and surface roughness. Yıldırım et al [28] analyzed the effect of cutting parameters and cooling and lubrication conditions on tool wear and surface roughness when milling on the basis of Waspaloy nickel ceramic tools. However, references [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] were not concerned with proposing the optimal position of the face mill and the workpiece that provides the minimum surface roughness.…”

Section: Introductionmentioning

confidence: 99%

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Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

et al. 2019

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In face milling one of the most important parameters of the process quality is the roughness of the machined surface. In many articles, the influence of cutting regimes on the roughness and cutting forces of face milling is considered. However, during flat face milling with the milling width B lower than the cutter’s diameter D, the influence of such an important parameter as the relative position of the face mill towards the workpiece and the milling kinematics (Up or Down milling) on the cutting force components and the roughness of the machined surface has not been sufficiently studied. At the same time, the values of the cutting force components can vary significantly depending on the relative position of the face mill towards the workpiece, and thus have a different effect on the power expended on the milling process. Having studied this influence, it is possible to formulate useful recommendations for a technologist who creates a technological process using face milling operations. It is possible to choose such a relative position of the face mill and workpiece that will provide the smallest value of the surface roughness obtained by face milling. This paper shows the influence of the relative position of the face mill towards the workpiece and milling kinematics on the components of the cutting forces, the acceleration of the machine spindle in the process of face milling (considering the rotation of the mill for a full revolution), and on the surface roughness obtained by face milling. Practical recommendations on the assignment of the relative position of the face mill towards the workpiece and the milling kinematics are given.

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Section: Introductionmentioning

confidence: 99%

“…Grzenda and Bustillo [34] examined the possibility of using unlabeled data streams to develop prediction models. However, papers [26][27][28][29][30][31][32][33][34] did not describe the optimum position of the face mill and the workpiece that provides the minimum surface roughness either.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

et al. 2019

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“…where σf max is the limit of bending strength. By substituting Equations (6)- (9) into Equation (5), the bending stress of the tool is The following formula can be obtained from Figure 18:…”

Section: Critical Conditions To Avoid Low-speed Breakagementioning

confidence: 99%

“…Changing the lubrication method can also increase the tool life. The comprised dry, wet, and minimum quantity lubrication (MQL) method was identified as the best cooling method for minimum tool wear and surface roughness [9]. Moreover, the fluid's content used in MQL has an influence on the chip morphology and tool performance [10].…”

Section: Introductionmentioning

confidence: 99%

Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

Wang

Zhou

et al. 2019

Metals

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The polycrystalline cubic boron nitride (PCBN) milling tool can be used in the mold industry to replace cemented carbide tools to improve machining efficiency and quality. It is necessary to study the tool wear and failure mechanism to increase machining efficiency and extend tool life. Cr12MoV is used to analyze the failure form of PCBN tools in the interrupted cutting of hardened steels at low and high speed conditions in milling experiments. Experimental results show that the failure forms of PCBN tools include chipping and flank wear at low speed, and the failure modes at high speed are flank wear, the surface spalling of the rake face, and the fatigue failure on the flank face. The failure mechanism of different failure forms is analyzed by observing the surface morphology of the tool and using the theory of fracture mechanics. The results show that a high cutting speed should be selected to avoid the early damage of low speed and achieve better application of PCBN tools. At high cutting speed, tool failure is mainly caused by mechanical wear, diffusion wear, and oxidation wear. Moreover, a fatigue crack will occur at the cutting edge on the chamfered tool under thermal-mechanical coupling because of the intergranular fracture of the CBN grain and binder. A large area of accumulated fatigue damage may appear due to the influence of alternating mechanical stress and thermal stress. Finally, the control method to avoid tool failure is presented.Metals 2019, 9, 885 2 of 15 nitride (PCBN) cutting tools are the preferred tool material due to excellent mechanical properties of higher hardness strength and wear resistance than other tool materials at high temperature. They are frequently used in the turning of hard and wear-resistant materials, such as hardened steels, superalloy, and even ceramics [11][12][13][14]. Numerous studies investigate the machining performance and tool life in PCBN hard turning [15][16][17]. Progressive flank wear, micro-chipping, and tool breakage easily occur due to critical crater wear [18]. For different cutting tools and workpiece materials, cutting speed is the main factor affecting the tool life, and it usually has a critical value after which the tool life of the cemented carbide tool will be lower than the PCBN cutting tool.In recent years, scholars have focused on the research of milling using the PCBN cutting tool. The results show that with a smaller cutting force [19], better surface quality [20], and a higher volume of metal removal [21] can be obtained by using PCBN tools compared with carbide-coated tools in processing hardened steel materials.It is observed that surface roughness (Ra) is in the range of 0.2 to 0.3 µm using a PCBN ball end tool, compared with 0.4 to 0.6 µm using the cemented tungsten carbide tool, at the cutting speed of 400 m/min in the milling of DIEVAR tool steel [22]. For milling, there is still a speed below which the tool life of cemented carbide is less than the tool life of PCBN. The life of cemented carbide tools can be higher than that of PCBN to...

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“…The ANN predictions are closer to actual results and thus efficiently predict the machining responses for a proper understanding of the complex cutting phenomena. In the recent investigation, Yıldırım et al [23] observed that the lowest wear among all type of tools is obtained under MQL machining, while the highest level of wear is obtained under wet cooling machining. Finally, MQL attributed the 17.34% and 433.67% better tool wear as compared to dry and wet cooling machining respectively.…”

Section: Introductionmentioning

confidence: 99%

Hard Turning on JIS S45C Structural Steel: An Experimental, Modelling and Optimisation Approach

Kumar¹,

Modi²,

Panda³

et al. 2019

IJAME

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The present research is performed while turning of JIS S45C hardened structural steel with the multilayered (TiN-TiCN-Al2O3-TiN) CVD coated carbide insert by experimental, modelling and optimisation approach. Herein, cutting speed, feed rate, and depth of cut are regarded as input process factors whereas flank wear, surface roughness, chip morphology are considered to be measured responses. Abrasion and built up-edge are the more dominant mode of tool-wear at low and moderate cutting speed while the catastrophic failure of tool-tip is identified at higher cutting speed condition. Moreover, three different Modelling approaches namely regression, BNN, and RNN are implemented to predict the response variables. A Back-propagation neural network with a 3-8-1 network architecture model is more appropriate to predict the measured output responses compared to Elman recurrent neural network and regression model. The minimum mean absolute error for VBc, Ra and CRC is observed to be as 1.36% (BNN with 3- 8-1 structure), 1.11% (BNN with 3-8-1 structure) and 0.251 % (RNN with 3-8-1 structure). A multi-performance Optimisation approach is performed by employing the weighted principal component analysis. The optimal parametric combination is found as the depth of cut at level 2 (0.3 mm)-feed at level 1 (0.05 mm/rev) – cutting speed at level 2 (120 m/min) considered as favourable outcomes. The predicted results were validated through a confirmatory trial providing the process efficiency. The significant improvement for S/N ratio of CQL is observed to be 9.3586 indicating that the process is well suited to predict the machining performances. In conclusion, this analysis opens an avenue in the machining of medium carbon low alloy steel to enhance the machining performance of multi-layered coated carbide tool more effectively and efficiently.

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Tool wear and surface roughness analysis in milling with ceramic tools of Waspaloy: a comparison of machining performance with different cooling methods

Cited by 70 publications

References 23 publications

Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

Hard Turning on JIS S45C Structural Steel: An Experimental, Modelling and Optimisation Approach

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