Dissertations / Theses on the topic 'Tool wear rate'

Milling is a commonly used machining process where a rotating cutter removes material from the workpiece. In recent years, attention has been turned towards so called dynamic milling methods which differ from the conventional way of milling. Dynamic milling normally uses, as opposed to the conventional way, more of the axial cutting edge, smaller radial depth of cut, significantly higher cutting speed and feed per tooth. The method has demonstrated potential to save both time and money under specific circumstances, for manufacturing companies.This thesis was conducted at ISCAR Sverige AB in Uppsala, Sweden. ISCAR Metalworking is a full service supplier of carbide cutting tools. The objective is to establish if there are benefits with dynamic milling methods with regard to material removal rate and lifetime of the tool by experimentally investigating and comparing tool wear that occur with conventional- and dynamic milling methods in hardened steels. Tools used were ISCAR’s MULTI-MASTER end mills, MM A and MM B, and the hardened steels were Hardox 600 and Dievar. Analysis was performed by using a USB-microscope, scanning electron microscope (SEM) and a Wyko-profilometer. The results of this study show that dynamic milling parameters can give several benefits regarding tool life and material removal rate. When machining in Hardox 600 and Dievar, both end mills were able to achieve a higher material removal rate and lifetime with dynamic parameters compared to more conventional ones. MM A outperformed MM B in Dievar, but the results were reversed in Hardox, MM B performed better. Results from the profilometry analysis showed that in Dievar, the dynamic parameters generated a smoother surface while the surface results from Hardox were more equivocal. The main conclusion was that milling with dynamic parameters is generally more advantageous and should be utilised, if possible.

Asphalt and concrete reclamation machines are used to cut roadways when a repair is required. The performance of these machines can affect the quality of road repairs, and cost/profitability for both contractors and governments. We believe that several performance characteristics in reclamation machines are governed by the placement and pattern of cutting picks on the cutter head. Previous studies, focused on mining and excavation applications, have shown strong correlation between placement and wear. The following study employs a screening experiment (observational study) to find significant contributors to tool wear, in applications of asphalt milling or reclamation. We have found that picks fail by two primary modes: tip breakage, and body abrasive wear. Results indicate that the circumferential spacing of a bit, relative to neighboring bits, has the strongest effect on tip breakage. We have also shown that bit skew angle has a large positive effect on body abrasive wear.

The search for increased productivity and cost reduction in machining can be interpreted as the desire to increase the material removal rate, MRR, and maximize the cutting tool utilization. The CNC process is complex and involves numerous limitations and parameters, ranging from tolerances to machinability. A well-managed preparation process creates the foundations for achieving a reduction in manufacturing errors and machining time. Along the preparation process of the NC-program, two different studies have been conducted and are presented in this thesis. One study examined the CAM programming preparation process from the Lean perspective. The other study includes an evaluation of how the cutting tools are used in terms of MRR and tool utilization. The material removal rate is defined as the product of three variables, namely the cutting speed, the feed and the depth of cut, which all constitute the cutting data. Tool life is the amount of time that a cutting tool can be used and is mainly dependent on the same variables. Two different combinations of cutting data might provide the same MRR, however the tool life will be different. Thereby the difficulty is to select the cutting data to maximize both MRR and cutting tool utilization. A model for the analysis and efficient selection of cutting data for maximal MRR and maximal tool utilization has been developed and is presented. The presented model shortens the time dedicated to the optimized cutting data selection and the needed iterations along the program development.

This research develops an analytical scientific approach for investigating the high precision surface generation and the quantitative analysis of the effects of direct factors in precision machining. The research focuses on 3D surface characterization with particular reference to the turning process and associated surface generation. The most important issue for this research is surface functionality which is becoming important in the current engineering industry. The surface functionality should match with the characterization parameters of the machined surface, which can be expressed in formula form as proposed in chapter 4. Modelling and simulation are extensively used in the research. The modelling approach integrates the cutting forces model, thermal mode% vibration model, tool wear model, machining system response model and surface topography model. All of those models are integrated as a whole model. The physical model with such as direct inputs is formed. The major inputs to the model are tooling geometry and the process variables. The outputs from the modelling approach are cutting force, surface texture parameters, dimensional errors, residual stress and material removal rate. MATLAB and Simulink are used as tools to implement the modelling and simulation. According to the simulation results, it is found that the feed rate has the most profound effect on in surface generation. The influence of the vibrations between the cutting tool and the workpiece on the surface roughness may be minimised by the small feed rate and large tool nose radius. Surface functionality simulation has been developed to model and simulate the surface generation in precision turning. The surface functionality simulation model covers the material and tool wear as well. It shows that chip formation is resulted from cutting forces. Cutting trials are conducted to validate the modelling and simulation developed. There are positive results that show the agreement between the simulation and experimental results. The analysis of the results of turning trials and simulations are conducted in order to find out the effects of process variables and tooling characteristics on surface texture and topography and machining instability. From the research, it can be concluded that the investigation on modelling and simulation of precision surfaces generation in precision turning is performed well against the research objectives as proposed. Recommendations for future work are to improve the model parameters identification, including comprehensive tool wear, chip formation and using Neural Networks modelling in the engineering surface construction system.

To survive in today's manufacturing environments companies must push the standards of accuracy and speed to the highest levels possible. Electro Discharge Machining (EDM) has been used for over 50 years and recent developments have seen the use of EDM become much more viable. The goal of this research is to produce and evaluate electrodes produced by different manufacturing methods. The use of electroforming and spray-metal deposition has only recently become viable methods of producing usable rapid tooling components. The speed and accuracy as well as the cost of manufacture play a vital role in the tool and mould manufacturing process. Electroforming and spray-metal deposition offer an alternate option to traditional machining of electrodes. Electroforming is one method of producing electrodes for EDM. The fact that electroforming can be used to produce multiple electrodes simultaneously gives it the advantage of saving on costs when multiple electrodes are needed. Spray-metal deposition offers another alternative that is much cheaper and relatively faster to manufacture. The used of these non-traditional manufacturing methods in this research are compared to the performance of traditional solid electrodes in terms of machining time, material removal rate, tool wear rates and surface roughness at several standard machining settings. The results of this research are presented in this thesis along with conclusions and comments on the performance of the different methods of electrode manufacture. The major findings of the research include the solid electrodes performed better than the electroformed electrodes in Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (Ra) at all machine settings. However it was found that the production cost of the solid electrodes was six times that of the electroformed electrodes. The production of spray metal electrodes was unsuccessful. The electrode shell walls were not an even thickness and the backing material broke through the shell making them unusable. It is concluded that with further refinements and research, electroforming and spray metal processes will become an extremely competitive method in electrode manufacture and other rapid tooling processes.

To survive in today's manufacturing environments companies must push the standards of accuracy and speed to the highest levels possible. Electro Discharge Machining (EDM) has been used for over 50 years and recent developments have seen the use of EDM become much more viable. The goal of this research is to produce and evaluate electrodes produced by different manufacturing methods. The use of electroforming and spray-metal deposition has only recently become viable methods of producing usable rapid tooling components. The speed and accuracy as well as the cost of manufacture play a vital role in the tool and mould manufacturing process. Electroforming and spray-metal deposition offer an alternate option to traditional machining of electrodes. Electroforming is one method of producing electrodes for EDM. The fact that electroforming can be used to produce multiple electrodes simultaneously gives it the advantage of saving on costs when multiple electrodes are needed. Spray-metal deposition offers another alternative that is much cheaper and relatively faster to manufacture. The used of these non-traditional manufacturing methods in this research are compared to the performance of traditional solid electrodes in terms of machining time, material removal rate, tool wear rates and surface roughness at several standard machining settings. The results of this research are presented in this thesis along with conclusions and comments on the performance of the different methods of electrode manufacture. The major findings of the research include the solid electrodes performed better than the electroformed electrodes in Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (Ra) at all machine settings. However it was found that the production cost of the solid electrodes was six times that of the electroformed electrodes. The production of spray metal electrodes was unsuccessful. The electrode shell walls were not an even thickness and the backing material broke through the shell making them unusable. It is concluded that with further refinements and research, electroforming and spray metal processes will become an extremely competitive method in electrode manufacture and other rapid tooling processes.

Aim master´s thesis is analyzed technological and economical parameters of cutting tool. Firstly there are the parameters cutting tool, cutting wear, economical parameters and costs on running tools specified. In the conclusion there are reach technological and economical parameters of cutting tools analyzed and tested on practical sample. The sample is part of attachments in form programme on calculation in Excel, together with evaluation by means of graphs.

Predmet istraživanja ove disertacije predstavlja unapređenje, modelovanje i optimizacija procesa elektroerozivne obrade (EDM) savremenih inženjerskih materijala. Prvo su predstavljene dve inovativne metode: EDM u dielektrikumu sa pome&scaron;anim prahom i EDM sa pomoćnom elektrodom, a zatim i njihova kombinacija. Za generisanje matematičkih modela primenjene su metodologija odzivne povr&scaron;ine i alati ve&scaron;tačke inteligencije. U nastavku su postavljeni optimizacioni procesi određivanja ulaznih parametara sa jednom i vi&scaron;e funkcija cilja koji su re&scaron;eni primenom klasičnih metoda optimizacije. U zavr&scaron;nom osvrtu sprovedena je verifikacija dobijenih modela i optimalnih ulaznih parametara elektroerozivne obrade.<br>The subject of the research of this dissertation is the improvement, modeling and optimization of the electrical discharge machining (EDM) of advanced engineering materials. First, two innovation methods are presented: EDM in powder mixed dielectric fluid and EDM with assisted electrode and that their combination. The method of response surface and artificial intelligence tools were applied to generate mathematical models. The optimization problems of determining the input parameters with single and multiple target functions are solved by the application of classical optimization methods. Finally, verification of the obtained models and optimal input parameters of electrical discharge machining was carried out.

Una base de datos de 33 km de registros de túnel de EPB en la zona de Barcelona se ha examinado en detalle desde el punto de vista de recambio de herramientas de corte y rendimiento de la excavación mecanizada. La base de datos incluye túneles en suelos blandos, en rocas medias y duras y en condiciones mixtas de roca y suelo. Los datos recabados incluyen registros de cambios de herramientas, operaciones de la maquina (avance, empuje, par, etc.) y propiedades geotécnicas, con un énfasis sistemático en mediciones de abrasividad de los diferentes materiales perforados. Para obtener una descripción homogénea de la abrasividad se realizaron mediciones de abrasividad del tipo LCPC en todos los materiales. Un resumen descriptivo de las principales tendencias reveladas por los datos se presenta en esta tesis. Las paradas de las máquinas durante la perforación se pueden clasificar entre aquellas debidas a un mantenimiento planificado y aquellas debidas a incidentes imprevistos. Los últimos pueden resultar ser decisivos cuando evaluamos el éxito de una perforación, aunque normalmente no son considerados en el proyecto. Uno de los aspectos más exigentes del mantenimiento desde el punto de vista operativo es el de las herramientas de corte, ya que su revisión y posible sustitución siempre implica paradas de la máquina, y como que a menudo es necesario tener acceso al frente, es con frecuencia una operación lenta y difícil. Por lo tanto, es deseable programar el mantenimiento de la cabeza de corte con la precisión máxima posible. Para llevar a cabo tal programación dos aspectos son necesarios: la identificación de ¿umbrales de desgaste¿ de las herramientas y un método que permita estimar el desgaste para cada herramienta como consecuencia de la operación. El objetivo de este estudio es investigar cómo enfrentarse a este problema cuando el medio es heterogéneo y la excavación es mecanizada mediante EPB. Se tiene en cuenta sistemáticamente la heterogeneidad geotécnica transversal y longitudinal. La heterogeneidad longitudinal se usa para segmentar la base de datos en unidades homogéneas. La heterogeneidad transversal (dentro de la sección) se estima por un conjunto de factores de impacto en la presente desarrollados FI. El concepto de energía específica (SE) fue aplicado para evaluar la eficiencia total de la excavación. Procedimientos anteriores para computar SE en excavaciones con TBM fueron adaptados a excavaciones con maquina EPB en modo cerrado. Se tienen en cuenta explícitamente el soporte del frente y el momento rotacional debido a la presión de la tierra. Varios métodos existentes para predecir la tasa de penetración y la vida útil de las herramientas se evalúan respecto a los resultados de la base de datos. Siempre que fuera necesario se realizaron recalibraciones de estos procedimientos. Basadas en un análisis sistemático de los resultados de la base de datos, se proponen nuevas relaciones de origen empírico para estimar la tasa de penetración a partir de otros parámetros operacionales y las propiedades del suelo promediadas por sección. La exactitud de algunas aproximaciones implicadas (concretamente el uso de un tiempo de vida útil equivalente) se ha encontrado razonable usando los resultados de una excavación con los datos que eran lo más exactos posibles. Las relaciones propuestas serian mayormente aplicables como puntos de partida en proyectos en los cuales la geología está compuesta de suelos y rocas blandas y donde son predominantes los frentes heterogéneos.<br>A database of 33 km of EPB tunnel records in the Barcelona area has been examined in detail from the point of view of cutting tool replacement and performance of the mechanized excavation. The database includes tunnels in soft soils, in hard and medium rocks and in mixed soil-rock conditions. Data gathered includes tool changing records, machine operation (advance, thrust, torque, etc.) and geotechnical properties, with a systematic emphasis on abrasivity measurements of the different materials perforated. To obtain a homogeneous description of abrasivity LCPC-type abrasive measurements were made in all the materials. A descriptive summary of the main trends revealed by the data is presented in this thesis. Machine downtimes during perforation can be classified into those due to planned maintenance and those due to unforeseen incidents. The latter can turn out to be decisive when assessing the success of a perforation, even though they are not usually considered in the project. One of the most demanding aspects of maintenance from an operational point of view is that of the cutting tools, since their revision and possible substitution always involves machine stops and, since it is often necessary to have access to the face, this is frequently a slow and difficult operation. Thus, it is desirable to schedule the cutter head maintenance operations with the highest possible precision. To carry out such scheduling two aspects are necessary: the identification of ¿wear thresholds¿ of the tools and a method that allows estimating the wear for each tool as a result of the operation. The objective of this study is to investigate how to tackle this problem when the media is heterogeneous and the excavation is mechanized by EPB. Transversal and longitudinal geotechnical heterogeneity is systematically accounted for. Longitudinal heterogeneity is used to segment the database in homogeneous units. Transversal (within section) heterogeneity is gauged by a set of newly developed impact factors FI. The specific energy concept (SE) was applied to evaluate overall excavation efficiency. Previous procedures to compute SE in TBM drives were adapted to excavations by EPB machine in closed mode. Face support and rotational moment due to earth pressure at the front face are taken explicitly into account. Several existing methods to predict penetration rate and tool service life are evaluated against the database results. Recalibrations of these procedures were performed when required. Based on a systematic analysis of the database results, new empirically based relations are proposed to estimate penetration rate from other operation parameters and section-averaged ground properties. The accuracy of some approximations involved (namely the use of an equivalent tool life time) has been found reasonable using the results of one drive were more exact computations were possible. The proposed relations would be mostly applicable as starting points in projects in which the geology is composed mostly of soils and soft rock and where the heterogeneous faces are predominant.

Limitation of conventional machining equipment has become a growing concern over the past two decades due to the demands for greater machining accuracy in today’s manufacturing. The development of micro-machining has therefore attracted significant attention; it signifies the advancement of national economy as well as the level of accuracy manufacturing industry could achieve. While the connection between tool lifespan, cost of machining and throughput is well established, the factor of tool lifespan appears to have more significance since the miniaturization of tool could lead to further performance concerns such as its lack of strength and durability. On the other hand, raising feed rate and spindle rotation speed are the two common approaches for increasing manufacturing throughput. Such approaches tend to cause an increase in the thrust force subjecting the tool to greater stress, which is the main cause of tool wear and even tool failure. Through literature review and preliminary experiments, it was found that spot-drill is often done prior to micro-drilling since it prepares a pre-drill countersunk hole that helps the alignment of tool for subsequent micro-drilling. Although such pre-drill step does improve the micro-drilling operation, the fundamental issue of tool diameter difference still remains. Often the tool used for pre-drill has a bigger diameter than the one for micro-drilling although a significant difference is always something to be avoided. This is because the difference has to be picked up by the tool used for micro-drilling and is directly linked to the wear caused by increased thrust force. In this research the operation of micro-drilling is investigated via mathematical models. Such operation is further broken down into various steps and stages so more detailed description can be achieved. The findings are then further enhanced by simulation based on the 3D model of micro-drilling. Three materials were selected for this research: Al 6061T, Al/Cu metal alloy panel and Carbon fibre reinforced composites. Such a selection enables the study of individual characteristics of different materials and the variation in respective thrust forces. Finally, Conclusions present the summary of the main findings from micro-drilling process analysis based on research and investigation shown in earlier chapters. By combining actual measurements on micro-drilling and mathematic model this research hopefully would improve the understanding towards micro-drilling processes.

碩士<br>國立成功大學<br>製造資訊與系統研究所<br>104<br>In this study, an automatic inspection system inspecting wear rate of drilling tool is developed to maintain the production process in good situation and to reduce defective products by making the right decision in different wear conditions. The inspection system of digital image process is developed with C# programming language. Digital single-lens reflex camera is used in the system to take picture. Before machining, the position of drilling tool would be inspected to make sure there is no holding abnormal. After machining, the inspection system is executed to measure wear rate of drilling tool instantly. If its wear rate does not exceed wear rate disable value (WRD), the drilling tool could be kept using in machining; otherwise, the drilling tool should be changed immediately. A wear rate control chart is also developed in this study to calculate wear rate reminded value (WRR). Along with the inspection system, an automatic connection system between computer and machining machine is designed. With such connection system, the inspection will start automatically from taking pictures to obtaining wear rate.

abstract: In this research, a new cutting edge wear estimator for micro-endmilling is developed and the reliabillity of the estimator is evaluated. The main concept of this estimator is the minimum chip thickness effect. This estimator predicts the cutting edge radius by detecting the drop in the chip production rate as the cutting edge of a micro- endmill slips over the workpiece when the minimum chip thickness becomes larger than the uncut chip thickness, thus transitioning from the shearing to the ploughing dominant regime. The chip production rate is investigated through simulation and experiment. The simulation and the experiment show that the chip production rate decreases when the minimum chip thickness becomes larger than the uncut chip thickness. Also, the reliability of this estimator is evaluated. The probability of correct estimation of the cutting edge radius is more than 80%. This cutting edge wear estimator could be applied to an online tool wear estimation system. Then, a large number of cutting edge wear data could be obtained. From the data, a cutting edge wear model could be developed in terms of the machine control parameters so that the optimum control parameters could be applied to increase the tool life and the machining quality as well by minimizing the cutting edge wear rate. In addition, in order to find the stable condition of the machining, the stabillity lobe of the system is created by measuring the dynamic parameters. This process is needed prior to the cutting edge wear estimation since the chatter would affect the cutting edge wear and the chip production rate. In this research, a new experimental set-up for measuring the dynamic parameters is developed by using a high speed camera with microscope lens and a loadcell. The loadcell is used to measure the stiffness of the tool-holder assembly of the machine and the high speed camera is used to measure the natural frequency and the damping ratio. From the measured data, a stability lobe is created. Even though this new method needs further research, it could be more cost-effective than the conventional methods in the future.<br>Dissertation/Thesis<br>Doctoral Dissertation Mechanical Engineering 2019

abstract: The demand for miniaturized components with feature sizes as small as tens of microns and tolerances as small as 0.1 microns is on the rise in the fields of aerospace, electronics, optics and biomedical engineering. Micromilling has proven to be a process capable of generating the required accuracy for these features and is an alternative to various non-mechanical micro-manufacturing processes which are limited in terms of cost and productivity, especially at the micro-meso scale. The micromilling process is on the surface, a miniaturized version of conventional milling, hence inheriting its benefits. However, the reduction in scale by a few magnitudes makes the process peculiar and unique; and the macro-scale theories have failed to successfully explain the micromilling process and its machining parameters. One such characteristic is the unpredictable nature of tool wear and breakage. There is a large cost benefit that can be realized by improving tool life. Workpiece rejection can also be reduced by successfully monitoring the condition of the tool to avoid issues. Many researchers have developed Tool Condition Monitoring and Tool Wear Modeling systems to address the issue of tool wear, and to obtain new knowledge. In this research, a tool wear modeling effort is undertaken with a new approach. A new tool wear signature is used for real-time data collection and modeling of tool wear. A theoretical correlation between the number of metal chips produced during machining and the condition of the tool is introduced. Experimentally, it is found that the number of chips produced drops with respect to the feedrate of the cutting process i.e. when the uncut chip thickness is below the theoretical minimum chip thickness.<br>Dissertation/Thesis<br>Masters Thesis Engineering 2015

Quality and productivity play significant role in today’s manufacturing market.From customers’ viewpoint quality is very important because the extent of quality of the procured item (or product) influences the degree of satisfaction of the consumers during usage of the procured goods. Therefore, every manufacturing or production unit should concern about the quality of the product. Apart from quality, there exists another criterion, called productivity which is directly related to the profit level and also goodwill of the organization. Every manufacturing industry aims at producing a large number of products within relatively lesser time. But it is felt that reduction in manufacturing time may cause severe quality loss. In order to embrace these two conflicting criteria it is necessary to check quality level of the item either on-line or off-line. The purpose is to check whether quality lies within desired tolerance level which can be accepted by the customers. Quality of a product can be described by various quality attributes. The attributes may be quantitative or qualitative. In on-line quality control controller and related equipments are provided with the job under operation and continuously the quality is being monitored. If quality falls down the expected level the controller supplies a feedback in order to reset the process environment. In off-line quality control the method is either to check the quality of few products from a batch or lot (acceptance sampling) or to evaluate the best process environment capable of producing desired quality product. This invites optimization problem which seeks identification of the best process condition or parametric combination for the said manufacturing process. If the problem is related to a single quality attribute then it is called single objective (or response) optimization. If more than one attribute comes into consideration it is very difficult to select the optimal setting which can achieve all quality requirements simultaneously. Otherwise optimizing one quality feature may lead severe quality loss to other quality characteristics which may not be accepted by the customers. In order to tackle such a multi-objective optimization problem, the present study applied extended Taguchi method through a case study in straight turning of mild viii steel bar using HSS tool. The study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality and as well as productivity with special emphasis on reduction of cutting tool flank wear. Because reduction in flank wear ensures increase in tool life. The predicted optimal setting ensured minimization of surface roughness, height of flank wear of the cutting tool and maximization of MRR (Material Removal Rate). In view of the fact, that traditional Taguchi method cannot solve a multi-objective optimization problem; to overcome this limitation grey relational theory has been coupled with Taguchi method. Furthermore to follow the basic assumption of Taguchi method i.e. quality attributes should be uncorrelated or independent. But is practical case it may not be so. To overcome this shortcoming the study applied Principal Component analysis (PCA) to eliminate response correlation that exists between the responses and to evaluate independent or uncorrelated quality indices called Principal Components. Finally the study combined PCA, grey analysis, utility concept and Taguchi method for predicting the optimal setting. Optimal result was verified through confirmatory test. This indicates application feasibility of the aforesaid techniques for correlated multi-response optimization and off-line quality control in turning operation.