Relevant bibliographies by topics / Textured insert; Tungsten carbide

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  1. Journal articles
  2. Dissertations / Theses
  3. Book chapters
  4. Conference papers

Academic literature on the topic 'Textured insert; Tungsten carbide'

Author: Grafiati
Published: 4 June 2021
Last updated: 11 February 2022

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Journal articles on the topic "Textured insert; Tungsten carbide"

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Palanisamy, D., K. Balasubramanian, N. Manikandan, D. Arulkirubakaran, and R. Ramesh. "Machinability analysis of high strength materials with Cryo-Treated textured tungsten carbide inserts." Materials and Manufacturing Processes 34, no. 5 (February 7, 2019): 502–10. http://dx.doi.org/10.1080/10426914.2019.1566612.

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Qi, Bao Yun, and Liang Li. "Experimental Study on Orthogonal Cutting of Ti6Al4V with Surface Micro-Groove Textured Cutting Tool." Materials Science Forum 723 (June 2012): 243–46. http://dx.doi.org/10.4028/www.scientific.net/msf.723.243.

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Currently biomimetic tribology study shows that high performance surface texture can achieve good friction, anti-adhesion and improve the wear resistance, which brings a new research direction for tool antifriction technology. The orthogonal cutting tests of surface micro-groove cutting tool in machining titanium alloy were presented. Different types of micro-grooves were made using laser in the rake face of uncoated tungsten carbide cutting inserts. Dry with no lubricant and minimal quantity lubricant (MQL) were used as lubrication conditions. Cutting force and cutting temperature were measured and compared. It was found that under MQL condition the surface micro-grooves could effectively improve the friction status between the tool and chip, thereby reducing cutting force and cutting temperature, and also reduce cutting temperature under no lubricant condition. The micro-grooves paralleling with cutting edge had the best effect in three types of micro-grooves.
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Manikandan, Natarajan, D. Arulkirubakaran, D. Palanisamy, and Ramesh Raju. "Influence of wire-EDM textured conventional tungsten carbide inserts in machining of aerospace materials (Ti–6Al–4V alloy)." Materials and Manufacturing Processes 34, no. 1 (November 28, 2018): 103–11. http://dx.doi.org/10.1080/10426914.2018.1544712.

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Lourenço, Nuno, Henrique Santos, and Carlos Sá. "The Use of Sodium Silicate to Improve Wetting of Tungsten Carbide Powder with Ductile Iron." Materials Science Forum 587-588 (June 2008): 118–22. http://dx.doi.org/10.4028/www.scientific.net/msf.587-588.118.

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A tungsten carbide insert is produced during ductile iron foundry practice to increase the surface hardness of the material. The insert is ensured with the help of a critical quantity of a binder, around 3 weight percent of sodium silicate, previously mixed with the tungsten carbide powder. The binder is verified to form a film around the tungsten carbide particles and bridges amongst these enveloped particles; these films and bridges are replaced by the ductile iron melt during the molding cavity filling. After solidification, a sound inserted layer is formed, composed of tungsten carbide particles in a tungsten enriched cast iron matrix. In the absence of the binder addition to the tungsten carbide powder no inserted layer is produced. The surface hardness of the inserted test pieces is close to 500VHN/4.9N and the respective thickness is around 2.5 mm. The characterization of the effect of the sodium silicate in the mixture has been the main purpose of this work
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Rana, Ramakant, R. S. Walia, and Qasim Murtaza. "Characterization and Parametric Optimization of Performance Parameters of DLC-Coated Tungsten Carbide (WC) Tool Using TOPSIS." Coatings 11, no. 7 (June 24, 2021): 760. http://dx.doi.org/10.3390/coatings11070760.

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In this work, we have deposited the diamond-like carbon (DLC) coating on the tungsten carbide (WC) tool insert using the thermal chemical vapor deposition (CVD) method. For the growth of DLC coating, sugarcane bagasse was used as a carbon precursor. Raman spectroscopy, a field emission scanning electron microscope (FESEM), and X-ray diffraction (XRD) were used to confirm the presence of DLC coating on the tungsten carbide tool inserts. The hardness tests were also performed for inspecting the microhardness induced by the self-developed DLC coating on the tungsten carbide (WC) tool insert. To determine the optimum process parameters for the turning operation on an aluminum (6061) workpiece using a self-developed DLC-coated tungsten carbide (WC) tool insert, we have applied the technique for order preference by similarity to ideal solution (TOPSIS) methods. The process parameters considered for the optimization were feed rate, cutting speed, and depth of cut. Whereas chosen response variables were flank wear, temperature in the cutting zone, and surface roughness. TOPSIS is utilized to analyze the effects of selected input parameters on the selected output parameters. This study in this paper revealed that it was advantageous to develop the DLC coating on the tungsten carbide tool inserts for the machining applications. The results also revealed that a 0.635 mm depth of cut, feed rate of 0.2 mm/rev, and cutting speed of 480 m/min were the optimum combination of process parameters.
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Siwawut, Sutham, Charnnarong Saikaew, and Anurat Wisitsoraat. "Effects of Number of Inserts and Insert Materials on Surface Roughness of Cast-Iron Work Produced by Face Milling." Advanced Materials Research 1016 (August 2014): 135–39. http://dx.doi.org/10.4028/www.scientific.net/amr.1016.135.

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In this work, the effects of two key factors of face milling including the number of inserts and insert material on surface roughness of cast-iron turbine housing work were systematically studied using full factorial designed experiments. Three insert materials including uncoated cemented carbide (TH10), commercial TiAlN/TiN coated cemented carbide (AH120) and tungsten carbo-nitride (WCN) coated cemented carbide were selected while the number of inserts was varied from 1 to 3 in this study. The results showed that both factors were statistically significant and the optimal parameters that yielded minimum Ra-value of 0.495 μm were the commercial TiAlN/TiN coated cemented carbide material (AH120) and three inserts.
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Sornakumar, T., and A. Senthil Kumar. "Machinability of bronze–alumina composite with tungsten carbide cutting tool insert." Journal of Materials Processing Technology 202, no. 1-3 (June 2008): 402–5. http://dx.doi.org/10.1016/j.jmatprotec.2007.10.013.

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Fábián, Enikő Réka, and Richard Horváth. "Adhesion Behavior of PVD-coated Cutting Tools." Acta Materialia Transylvanica 3, no. 2 (October 1, 2020): 61–64. http://dx.doi.org/10.33924/amt-2020-02-01.

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Abstract Cutting with TiAlN or CrAlN tip PVD-coated tungsten carbide-based inserts manufactured by powder metallurgy, we found no significant difference in the wear behavior of inserts regardless of whether the insert was used in wet or dry conditions. We determined the adhesion properties of the coating layers with a scratch test and by Daimler–Benz test. On the tungsten-based carbide cutting tool, the thinner TiAlN coating showed slightly better adhesion than the thicker CrAlN coating.
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Kim, Jong Seok, Yeong Min Park, Jeong Wan Kim, Kelimu Tulugan, and Tae Gyu Kim. "Characteristics of deposited boron doping diamond on tungsten carbide insert by MPECVD." Modern Physics Letters B 29, no. 06n07 (March 20, 2015): 1540048. http://dx.doi.org/10.1142/s0217984915400485.

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Diamond-coated cutting tools are used primarily for machining non-ferrous materials such as aluminum–silicon alloys, copper alloys, fiber-reinforced polymers, green ceramics and graphite. Because the tool life of cemented carbide cutting tool is greatly improved by diamond coating, and typically more than 10 times of the tool life is obtained. However, research of boron-doped diamond (BDD) coating tool has not been fully researched yet. In this study, we have succeeded to make boron-doped microcrystalline and nanocrystalline diamond-coated Co -cemented tungsten carbide (WC– Co ) inserts. Microcrystalline BDD thin film is deposited on WC– Co insert by using microwave plasma enhanced chemical vapor deposition (MPECVD) method. Scanning electron microscope (SEM) and Raman spectroscopy are used to characterize the as-deposited diamond films.1,2
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Tarraste, Marek, Jakob Kübarsepp, Arvo Mere, Kristjan Juhani, Märt Kolnes, and Mart Viljus. "Ultrafine Cemented Carbides with Cobalt and Iron Binders Prepared via Reactive In Situ Sintering." Solid State Phenomena 320 (June 30, 2021): 176–80. http://dx.doi.org/10.4028/www.scientific.net/ssp.320.176.

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Reactive sintering of cemented carbides involves mechanical and thermal activation of precursor elemental powders, followed by in-situ synthesis of tungsten carbide. This approach promotes formation of ultrafine microstructure favored in many cemented carbide applications. Our study focuses on the effect of mechanical activation (high-energy milling) on the properties of powder and following thermal activation (sintering) on the microstructure characteristics and phase composition. Reactive sintering proved effective – an ultrafine grained microstructure of cemented carbides with Co and Fe binders was achieved. Formation of tungsten carbide grains was complete at low temperature during reactive spark plasma sintering, resulting in textured microstructure with anisotropic grain formation and growth.
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Dissertations / Theses on the topic "Textured insert; Tungsten carbide"

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Tamil, Alagan Nageswaran. "Textured insert for improved heat extraction in combination with high-pressure cooling in turning of superalloys." Licentiate thesis, Högskolan Väst, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT), 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-11738.

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Heat generated in a machining process is a common and critical obstacle faced in today's machining industries. The heat generated in the cutting zone has a direct negative influence on the tool life which, in turn contributes to increase the manufacturing costs. Especially, in machining of Heat Resistant Super Alloys, HRSA this is a very limiting factor. HRSA are capable of retaining their mechanical strength and hardness at elevated temperatures. This property is advantageous in the application in e.g. aero-engines but also a disadvantage, since it also lowers the machinability significantly. This work is an attempt to improve the heat transfer from the cutting zone, which would lead to an increase in the tool life. To achieve this goal, the cutting tool has been modified to create an improved interface between the coolant and tool in the high-temperature areas. Two generations of inserts have been designed and investigated. Firstly, an insert with surface texture features has been created with the purpose of increasing the available surface area for heat dissipation: First generation, Gen I. Secondly, a GenII was designed as a further improvement of Gen I. Here, several channel features on the rake face were added, reaching out from the contact zone to the near proximity of the cutting edge. This with the purpose of improving access of the coolant closer to the cutting edge. The experiments were conducted in facing operations of Alloy 718 with uncoated round carbide inserts. All experiments were carried out with high-pressure coolant assistance, with a pressure of 16 MPa on the rake face and 8 MPa on the flankface, respectively.The two generations of inserts, Gen I and Gen II, were experimentally evaluated by tool wear analysis in comparison with a regular insert. The results shows that the tool life increased significantly for the Gen I insert, compared to a catastrophic failure of the regular insert at the same conditions. Regarding the Gen II insert,an increase in tool life by approximately 30 to 40 percent compared to Gen I insert was observed.
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Marou, Alzouma Ousseini. "Durabilité tribologique de matériaux pour insert de dents de tunnelier." Thesis, Ecully, Ecole centrale de Lyon, 2015. http://www.theses.fr/2015ECDL0042.

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La fréquence des opérations de maintenance lors de l’excavation du sol par les tunneliers est problématique pour les entreprises de travaux publics. Ces opérations de maintenance engendrent des temps morts onéreux et nécessitent l'intervention d'opérateurs dans des conditions de travail hyperbares. Une des raisons aux nombreuses interventions humaines pour la maintenance est l’endommagement des outils racleurs du sol excavé (dents) qui sont placés sur la tête du tunnelier. Ces outils sont sujets à l’usure compte tenu de l’abrasivité des différents milieux qu’ils rencontrent. Le but de cette thèse est de contribuer à augmenter d’au moins 20% la durée de vie des matériaux constitutifs de ces outils, afin de réduire les différentes opérations de maintenance qui exposent les opérateurs à des risques importants. Pour atteindre cet objectif, les investigations menées dans ce travail ont porté sur plusieurs axes. Dans un premier temps, une expertise est menée pour identifier les modes d’endommagement prédominants sur les inserts à base de carbure de tungstène placés sur les dents ; ensuite, de nouveaux matériaux avec des propriétés mécaniques et des microstructures optimisées, développés dans le cadre du projet européen NeTTUN, sont caractérisés sur des bancs d’essais représentatifs. Ces essais ont permis de bien comprendre les mécanismes d’usure des nouveaux matériaux à base de carbure de tungstène. Les résultats de ce travail peuvent ensuite donner lieu à de nouvelles orientations en matière de choix de matériaux pour renforcer les dents de tunnelier
The frequency of maintenance operations during the excavation of the ground by the tunnel boring machines (TBM) is problematic for civil engineering companies. These maintenance operations provoke expensive timeouts and they bring in excavation operators in risky hyperbaric work conditions. One of the reasons which leads to the numerous human interventions for the maintenance is the damage of drag bits located on the cutting wheel of the TBM. These drag bits undergo wear due to the abrasiveness of the various media they meet. The purpose of this thesis is to contribute to increase by 20 % at least the lifetime of the materials of the dag bits, in order to reduce the various maintenance operations which expose the operators to important risks. To achieve this goal, the investigations led in this work concerned several axes. At first, an expertise is led to identify the wear modes prevailing on the carbide inserts located on the drag bits; then, new materials with enhanced mechanical properties and optimized microstructures, developed in the framework of the European project NeTTUN, are characterized on representative lab testing devices. These tests allowed us to understand well the wear mechanisms of the newly developed grades of tungsten carbides. The results of this work can lead to new strategies for the selection of materials to reinforce the drag bits
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Durand, Corinne. "Atomisation de gouttes liquides sur une cible tournante microstructurée." Thesis, Grenoble, 2014. http://www.theses.fr/2014GRENI035.

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L’objectif de ce travail est de concevoir un outil d’atomisation adapté à la production de poudres de carburede tungstène dans l’entreprise Technogenia, située à Saint-Jorioz (74). Plus généralement, nous avons étudiéune nouvelle conception d’atomiseur rotatif pour lequel les surfaces d’atomisation sont orientées selon un angled’incidence non nul. Une telle orientation permet alors d’exploiter de façon plus efficace la fréquence de rotationde l’atomiseur ainsi que les forces de centrifugation et de Coriolis. A partir de cette base de réflexion, troisgéométries de surface d’atomisation ont été étudiées : des surfaces lisses, des surfaces pourvues de structurationsde long de leur bord de fuite et des surfaces matricées de perforations.Les différents modes de déstabilisation des écoulements liquides ont été observés grâce à l’acquisition de vidéosultra-rapides des différentes étapes de l’impact d’une goutte unique sur les différentes géométries de surfacesd’atomisation étudiées. Les processus d’atomisation peuvent ainsi varier entre la rupture de jets liquides régulierscausée par des instabilités de type Rayleigh-Plateau et la rupture de nappes liquides causée par des instabilitésde type Rayleigh-Taylor et/ou l’initiation de perforations au coeur des nappes et films liquides. Les vidéos dessprays aqueux ainsi que l’observation au microscope des poudres métalliques nous permettent de caractériser lessprays produits. Sur l’ensemble de nos expériences nous observons que la finesse de l’atomisation s’améliore àmesure que la fréquence de rotation augmente ; ce qui constitue l’objectif prioritaire du procédé développé dans lathèse. Cependant, les surfaces texturées, certes compatibles avec les liquides classiques (aqueux ou organiques),ne le sont plus avec les contraintes induites par du métal à haute température de fusion, tel le carbure detungstène fondu objet de la thèse. En conséquence, seules les surfaces lisses sont aujourd’hui retenues et fontl’objet de développements dans le cadre de la production de poudres métalliques au sein de Technogenia
The aim of this work is to design a spray tool for the production of tungsten carbide powder for the companyTechnogenia, located in Saint-Jorioz (74). Thus, we have studied a new design of rotary atomizer based onatomization surface oriented at a non-zero incidence angle. Such an orientation can then allow to use moreeffectively the rotation frequency of the atomizer and the centrifugal and Coriolis forces. From this base reflection,three geometries of atomization surface were studied : smooth surfaces, surfaces with serrated structurationsalong their trailing edge and multi-perforated surfaces.The different destabilization modes of liquid flows were observed through high-speed videos of the different stagesof the single drop impact on each atomization surfaces. The atomization process can thus vary between liquid jetbreakup caused by Rayleigh-Plateau instabilities and liquid sheet breakup caused by Rayleigh-Taylor instabilitiesand/or initiating of holes in liquid films or sheets. Videos of aqueous sprays and microscopic observation of metalpowders allow us to characterize sprays. On all of our experiments, we observe that the atomisation gets better(producing finer spray), as the frequency of rotation increases. Although the textured surfaces are compatiblewith usual liquids (aqueous or organical), they can’t stand the constraints imposed by metal with a high meltingtemperature such as tungsten carbide, the object of this thesis. Therefore, only the smooth surfaces are nowthe subject of an industrial development to produce metallic powder with Technogenia company
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Book chapters on the topic "Textured insert; Tungsten carbide"

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Adam Khan, M., and Kapil Gupta. "Optimization of Machining Parameters for Material Removal Rate and Machining Time While Cutting Inconel 600 with Tungsten Carbide Textured Tools." In Intelligent Manufacturing, 37–56. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-50312-3_2.

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Slipchuk, Andrii, Roman Jakym, Vladimir Lebedev, and Emil Kurkchi. "The Influence of Technological Factors on the Reliability Connection for Tungsten Carbide Insert Cutter with Cone in the Roller Cone Bits." In Lecture Notes in Mechanical Engineering, 443–52. Cham: Springer International Publishing, 2021. http://dx.doi.org/10.1007/978-3-030-68014-5_44.

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Conference papers on the topic "Textured insert; Tungsten carbide"

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Ma, J., Hung Duong, Yunsong Lian, and Shuting Lei. "Assessment of Microgrooved Cutting Tool in Dry Machining of AISI 1045 Steel: A Numerical Study." In ASME 2013 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/imece2013-63842.

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This paper studies the performance of microgrooved cutting tool in dry orthogonal machining of mild steel (AISI1045 steel) using Finite Element (FE) simulation to gain insights into how to improve performance of cutting tools. Microgrooves are designed on the rake face of tungsten carbide (WC) cutting inserts. The purpose is to test the effect of microgroove textured tools on machining performance and to compare it with non-textured cutting tools. Specifically, the following groove parameters are examined: groove width, groove depth, edge distance (the distance from cutting edge to the first groove). Their effects are assessed in terms of cutting force and thrust force. It is found that microgrooved cutting tools generate lower cutting force and thrust force and consequently lower the energy necessary for machining. The groove width, groove depth, and edge distance have big influence on the cutting force and thrust force. Consequently, this research provides insightful guidance for optimizing cutting tools.
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Carlos Artur Alevato Leal, Alexandre Mendes Abrao, Lincoln Cardoso Brandão, Carlos Eiji Hirata Ventura, Berend Denkena, Bernd Breidenstein, and Benjamin Bergmann. "EXPERIMENTAL STUDY ON TURNING OF GRAY CAST IRON USING TEXTURIZED TUNGSTEN CARBIDE INSERTS." In 23rd ABCM International Congress of Mechanical Engineering. Rio de Janeiro, Brazil: ABCM Brazilian Society of Mechanical Sciences and Engineering, 2015. http://dx.doi.org/10.20906/cps/cob-2015-0704.

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Chao, Choung-Lii, Chia-Jung Chang, Chun-Chieh Chen, Wen-Chen Chou, and Kung-Jeng Ma. "Precision grinding of tungsten carbide mold insert for molding of sub-millimeter glass aspheric lenses." In International Conference on Optics in Precision Engineering and Nanotechnology (icOPEN2013), edited by Chenggen Quan, Kemao Qian, and Anand Asundi. SPIE, 2013. http://dx.doi.org/10.1117/12.2021120.

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"Examining the role of cutting fluids in machining AISI 1040 steel using tungsten carbide insert under minimal quantity lubrication condition." In 3rd International Conference on Advances in Engineering Sciences and Applied Mathematics. International Institute of Engineers, 2015. http://dx.doi.org/10.15242/iie.e0315066.

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Arner, Kenneth A., Christopher D. Agosti, and John T. Roth. "Effectiveness of the Cryogenic Treatment of Tungsten Carbide Inserts on Tool Wear When in Full Production Operations." In ASME 2004 International Mechanical Engineering Congress and Exposition. ASMEDC, 2004. http://dx.doi.org/10.1115/imece2004-60059.

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As a cutting tool wears, the quality of the parts being produced by the tool are reduced. Therefore, it is important to change cutting tools whenever the wear on the tool begins to cause unacceptable or out-of-specification parts. However, frequent replacement of tooling is not only expensive, it also results in a loss of production throughput. Therefore, in order to lower tooling costs and increase production rates, it is vital to extend cutting tool life. Thus, this research focuses on establishing the effect that cryogenically treating carbide inserts has on the overall tool life when the tools are operating in production. To validate the effectiveness, multiple treated and untreated cutting tools for five styles of inserts are examined. The cutters are tested in production lines that are fabricating parts for an industrial partner where the only process variable that is changed is the cryogenic treatment of the tooling. For the five insert styles tested, each style provided very consistent changes in overall tool life. However, the amount of improvement was dependent on the tool style. One style was found to have its life doubled, whereas, another style had its life decreased. Possible causes for this difference in effectiveness of the treatment are presented, along with a discussion concerning the actual costs savings that the treatment represents for the industrial partner.
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Schrock, David, Xin Wang, and Patrick Kwon. "An Analysis of the Wear of Tungsten Carbide and Polycrystalline Diamond Inserts Turning Ti-6Al-4V." In ASME 2011 International Manufacturing Science and Engineering Conference. ASMEDC, 2011. http://dx.doi.org/10.1115/msec2011-50175.

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Dry turning experiments on Ti-6Al-4V were conducted using two grades (finer and coarser) of carbides and polycrystalline diamond (PCD) inserts to study tool wear. Despite of minor compositional difference between two carbide grades, both grades contain 6% Co. Crater wear and flank wear were measured using Confocal Laser Scanning Microscopy (CLSM). Three dimensional rake surface topographies were reconstructed from the CLSM data and wear profiles were extracted. Finite Element Analysis (FEA) was conducted to study the effects of cutting conditions and thermal properties on rake face temperature. Flank wear on the carbide tools indicated that the inserts with the finer grain size exhibited smaller flank wear than the insert of the coarser grain size. This was attributed to reduced abrasive wear in the finer grained inserts as a result of a higher hardness. The carbide grade with a coarser grain size had an enhanced ability to resist crater wear, likely from lower rake face temperatures and the differences in the compositions. It is known that coarser grain carbides have a higher thermal conductivity resulting from increased grain contiguity. FEA was used to study the temperature difference between the two grain-sizes and the effect of thermal conductivity on temperature gradients. Tool wear of the PCD inserts was also studied. The PCD tools showed significant adhesive wear at the 200sfm cutting speed, transitioning to crater wear at 400sfm. With a high thermal conductivity, it is possible that rake face temperatures were low enough to alter the wear mechanism. FEA supports this hypothesis, as the maximum rake face temperature for the PCD inserts were only around 900°C at 200sfm.
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Kesriklioglu, Sinan, Justin D. Morrow, and Frank E. Pfefferkorn. "Tool-Chip Interface Temperature Measurement in Interrupted and Continuous Oblique Cutting." In ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/msec2017-2934.

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The objective of this work is to fabricate instrumented cutting tools with embedded thermocouples to accurately measure the tool-chip interface temperature in interrupted and continuous turning. Thin-film thermocouples were sputtered directly onto the flat rake face of a commercially available tungsten carbide cutting insert using micro machined stencils and coated the measurement junction with a protective layer to obtain temperature data 1.3 μm below the tool-chip interface. Oblique interrupted cutting tests on AISI 12L14 steel were performed to observe the influence of varying cutting speeds and cooling intervals on tool chip interface temperature. An additional cutting experiment was conducted to monitor the interface temperature change between interrupted and continuous cuts.
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Scott, Dan E., and Marc R. Skeem. "Diamond Enhanced Shear Cutting Elements on Roller Cone Bits." In ASME 2001 Engineering Technology Conference on Energy. American Society of Mechanical Engineers, 2001. http://dx.doi.org/10.1115/etce2001-17031.

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Abstract Polycrystalline diamond (PCD) cutters and drag bit designs have been substantially improved since their 1972 introduction, and PCD drill bits now are approaching the rolling cone tungsten carbide insert (TCI) market is terms of revenue size and have surpassed it in terms of economic impact on the drilling industry.1,2 These performance improvements have lead to a significant encroachment into the drill bit market built upon the breakthrough invention of the rolling cone bit by Howard Hughes Sr. Material and design improvements in the last decade, however, have now led to the successful application of patented shear cutting PCD elements as well as conventional diamond enhanced crushing style inserts on rolling cone bits. Diamond enhanced rolling cone bits are also a growth market for diamond elements in drilling. Failing rock in shear is a more efficient process than by crushing, but most cutting materials can not stand up to the forces generated in the shearing process as rock strength increases. To take advantage of the unique ability of the PCD cutter to shear rock efficiently, a concerted R&D effort supported by laboratory and field-testing led to the application of diamond as a shear cutting element on roller cone bits. A variety of rolling cone shear cutting elements have been developed and successfully commercialized in the last decade. This paper will discuss laboratory results and increased field performance achieved relative to conventional crushing style diamond and tungsten carbide inserts. The authors will document through case studies increases in rate of penetration (ROP), footage, overall durability, and gauge holding ability in addition to bearing/seal effectiveness that have further reduced drilling costs and served to increase usage of polycrystalline diamond elements on roller cone bits. These applications range from such diverse markets as high cost offshore North Sea, to low cost North American land operations.
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Al-Salah, Fawaz, Saad Al-Mejmed, Atef Abdelhamid, Ali Alnemer, Tahir Gada, and Mehul Pandya. "Hybrid Bit Technology Deployment Yields Breakthrough Drilling Performance & Cost Savings for Operator." In IADC/SPE Asia Pacific Drilling Technology Conference. SPE, 2021. http://dx.doi.org/10.2118/201018-ms.

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Abstract Optimized drilling performance and minimized cost per well are key objectives for operators in the current challenging oil and gas industry. The process of collecting lessons learned and designing new drill bit technologies based on these learnings is critical for optimizing drilling performance and reducing non-productive time (NPT). Southeast Kuwait onshore wells are drilled with conventional drill bit technology such as tungsten carbide insert (TCI) and polycrystalline diamond compact (PDC) bits on rotary or directional-motor bottom hole assemblies (BHA). This paper discusses the analysis that enabled breakthrough-drilling performance of 16-in. hybrid drill bit technology, delivering outstanding results and cost savings for an operator. The non-homogeneous carbonate formation in these onshore wells cause impact damage, limit the drilling efficiency of PDC and TCI bits, and result in a low rate of penetration (ROP) and poor dull conditions. A collaborative technical analysis identified key performance objectives to ensure a step change in section drilling performance. The analysis involved reviewing: Post-run dull conditions Operating parameters Formation compressive strengths Bit design Previous deployments results On Multiple wells, advanced hybrid bit technology and optimized drilling methods achieved outstanding 73-percent improvement in ROP over conventional technologies, saving operator's 3.8 drilling days and more than 27% of drilling costs. The hybrid design completed two consecutive best in class (BIC) wells in southeast Kuwait compared with the typical TCI performance of a single well per bit.
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Cardoe, Jennifer, Gunnar Nygaard, Christopher Lane, Tero Saarno, and Marc Bird. "Oil and Gas Drill Bit Technology and Drilling Application Engineering Saves 77 Drilling Days on the World’s Deepest Engineered Geothermal Systems EGS Wells." In SPE/IADC International Drilling Conference and Exhibition. SPE, 2021. http://dx.doi.org/10.2118/204121-ms.

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Abstract An Engineered Geothermal System (EGS) pilot project was commissioned to prove the economic viability of an industrial scale geothermal heat plant in Finland. The project aims to generate 40 MW of emission free heat energy, supplying up to 10% of the city of Espoo’s district heating needs. Two wells of 6400 m MD and 6213 m MD (measured depth) were drilled through formations of hard, abrasive granitic gneiss with maximum measured 560 MPa UCS (unconfined compressive strength). Typical dull conditions of lost and worn cutting structure and gauge diameter wear of between 3/16-in to ¼-in contributed to excessive torque, stuck incidences, low rate of penetration (ROP) and difficulties achieving build rate. To address these drilling challenges, this paper explores the interplay between new cemented carbide compact technology, drill bit design, and drilling parameter road mapping. The directional section of the first well was drilled with an average ROP below 2 m/hr and run length averaging 56 m per bit. The well took 246 drilling days and 44 BHAs (bottom hole assemblies) to achieve TD (total depth). Between the first and second well an application specific drill bit design package and step-wise parameter program were implemented. Design enhancements included improved gauge protection, bit hydraulics for minimizing cone erosion and subsequent TCI (tungsten carbide insert) compact loss. Novel hybrid TCI materials technology was introduced having a 100% improvement in wear resistance and durability as compared with conventional grades, to drill these hard and abrasive granitic formations. New BHAs and drilling plan were selected based on the bit design selection to reduce wear on BHA components, improve directional control and reducing drilling dysfunctions. Once these factors were under control, a low risk approach to extending the bit revolution limits (krev) for the roller cone sealed bearings could be implemented based on downhole parameters and previous bit dulls, leading to longer run lengths. The combination of bit design and material enhancements with a properly selected BHA and drill plan increased run lengths and ROP. The second well’s 8.5-in directional section was drilled with a 13% increase in average ROP and a 69% increase in average run length without exceeding krev limits. Well on well, a 77 day reduction in AFE (authorization for expenditure) was realized. We demonstrated the combination of oil and gas bit and BHA design, drilling plan, and new cutting material capabilities can reduce EGS well construction costs in order to make these renewable energy sources economical.
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