Journal articles: 'Tool wear rate'

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Zhang, Ziqi, Zhanqiang Liu, Xiaoping Ren, and Jinfu Zhao. "Prediction of Tool Wear Rate and Tool Wear during Dry Orthogonal Cutting of Inconel 718." Metals 13, no. 7 (2023): 1225. http://dx.doi.org/10.3390/met13071225.

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A new prediction method was proposed based on the positive feedback relationship between tool geometry and tool wear rate. Dry orthogonal cutting of Inconel 718 was used as a case study. Firstly, tool wear rate models and a tool wear prediction flowchart were proposed. Secondly, the evolution of the tool geometry during tool wear was analyzed considering the combined effect of tool crater wear and tool flank wear. Thirdly, the evolution of the cutting temperature, normal stress and tool–chip relative sliding velocity on the tool wear surface was studied, the evolution of the tool wear rate during tool wear was revealed. Finally, the evolution of the tool geometry and tool wear rate during tool wear were applied to the tool wear prediction method to accurately predict the tool wear. The prediction error of KT is less than 15% in comparison with the experimental results. The tool wear prediction method in this paper is helpful to improve the prediction accuracy of tool crater wear.

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Meng, Xinxin, Youxi Lin, Shaowei Mi, and Pengyu Zhang. "The Study of Tool Wear Mechanism Considering the Tool–Chip Interface Temperature during Milling of Aluminum Alloy." Lubricants 11, no. 11 (2023): 471. http://dx.doi.org/10.3390/lubricants11110471.

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ADC12 aluminum alloy has been widely used in the aerospace, ship, and automotive fields because of its high specific strength, excellent die-casting performance, and wear resistance. Adhesion wear is the main wear mechanism of high-speed milling ADC12 aluminum alloy. The most important factor affecting adhesion wear is the tool–chip interface friction, which is directly manifested in the tool–chip interface temperature. Therefore, the temperature variation during the milling of aluminum alloy is analyzed using a temperature field model and infrared temperature measurement technology. Then, the tool wear morphology and the tool wear land width are observed using a scanning electron microscope. Finally, the tool wear mechanism considering the tool–chip interface temperature is discussed. The tool–chip interface temperature is related to the friction angle, tool–chip contact length, and friction force at the rake face, which increases first and then decreases as the cutting speed and feed rate increase. During the formation of the adhesive layer, the tool–chip interface temperature increases, the change rate of the cutting force and the tool wear rate increase, and adhesion, oxidation, and abrasive and delamination wear are generated on the tool surface. With the increase in temperature, the tool wear rate increases, the molten adhesive layer on the tool surface is accompanied by crack propagation, and adhesion wear, oxidation wear, and abrasive wear occur on the tool surface.

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Parkash, Ved, and Deepak Kumar. "Effect of Powder Mixed Dielectric Medium on Tool Wear Rate in EDM." International Journal of Scientific Research 2, no. 2 (2012): 107–9. http://dx.doi.org/10.15373/22778179/feb2013/38.

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Castro, Fernando Luiz, Denis Boing, and Rolf Bertrand Schroeter. "Tool Performance Assessment based on Three-Dimensional Tool Wear Rate." Procedia CIRP 77 (2018): 638–41. http://dx.doi.org/10.1016/j.procir.2018.08.188.

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Xie, L. J., D. Zheng, C. Schmidt, and J. Schmidt. "Estimate of Tool Wear in Milling Operation Based on “Differential” Wear Rate Model." Applied Mechanics and Materials 10-12 (December 2007): 786–90. http://dx.doi.org/10.4028/www.scientific.net/amm.10-12.786.

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Many research show that in metal cutting process wear rate is dependent on the cutting process variables such as temperature at tool face, contact pressure (normal stress) and relative sliding velocity at tool/chip and tool/work interface; their relationship is described by “differential” wear rate model. Based on this “differential” wear rate model, a method to estimate tool wear in milling operation is proposed and the cutting process variables are predicted by performing chip formation analysis with FEM code ABAQUS/Explicit and heat transfer analysis with ABAQUS/Standard. The implementation is exemplified by estimating tool wear of carbide tools in milling of Ck45 work. Both progressive flank wear and crater wear profile are estimated.

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Zhou, Zhi Min, Xiao Yan Li, Yuan Xin Qu, and Jian Na. "Tool Wear of Diamond Tools in Ultrasonic Vibration Turning Titanium Alloys." Applied Mechanics and Materials 229-231 (November 2012): 517–20. http://dx.doi.org/10.4028/www.scientific.net/amm.229-231.517.

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Titanium alloys, as difficult-to-cut materials, have poor machinability due to their superior mechanical properties, heat resistance and corrosion resistance. High cutting temperature and great cutting force that will greatly accelerate tool wear often occurs in titanium alloys cutting process. In this paper, an ultrasonic vibration turning method was used to lower diamond tool wear during TC4 titanium alloy turning process. Ultrasonic vibration turning tests were carried out with various cutting parameters. Experimental results indicated that there’s a significant reduction of the wear rate of diamond tools by means of ultrasonic vibration in TC4 turning process. For ultrasonic vibration turning, spindle speed, the amplitude and frequency of vibration of the tool are the greatest impact of tool wear, followed by feed rate, then the cutting depth.

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Sagar, Chithajalu Kiran, Amrita Priyadarshini, Amit Kumar Gupta, and Devanshi Mathur. "Experimental investigation of tool wear characteristics and analytical prediction of tool life using a modified tool wear rate model while machining 90 tungsten heavy alloys." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, no. 1-2 (2020): 242–54. http://dx.doi.org/10.1177/0954405420933113.

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Tungsten heavy alloys are widely used in the manufacturing of weights for aircraft, missiles, boats and race cars; penetrators; radiation shielding; and radioisotope containers. Manufacturing these components needs machining as a secondary operation. Since tungsten heavy alloys are difficult to machine, the in-depth analysis of tool wear growth and mechanism during machining of these alloys becomes essential. Hence, this work focuses on the experimental study of flank wear growth and its effect on other machining outputs for two different tool geometries (−5° and 2° rake angles) during turning of 90 tungsten heavy alloys. The predominant wear mechanism was identified as adhesion based on scanning electron microscopic analysis. Finally, three commonly used analytical tool wear rate models and one newly proposed model (modified Zhao model) were utilized for the prediction of flank wear growth and tool life. It was observed that the modified Zhao model could predict tool flank wear fairly well within error percentage of 4%–7% and thus could be used as a benchmark while machining difficult-to-cut alloys.

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Dureja, J. S., V. K. Gupta, V. S. Sharma, and M. Dogra. "Wear mechanisms of coated mixed-ceramic tools during finish hard turning of hot tool die steel." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 224, no. 1 (2009): 183–93. http://dx.doi.org/10.1243/09544062jmes1691.

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The present study aims to investigate the wear mechanisms of a TiN-coated mixed ceramic tool prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed are abrasion wear at low cutting speed, low feed rate, and highest work piece hardness; formation of protective layer and built-up edge (BUE) resulting from tribochemical reactions between constituents of tool and work piece material at moderate speed. High temperature accompanied by high cutting speed resulted in the removal of the protective layer and suppressed the BUE formation. Hard carbide particles of work material at a higher feed rate severely gouged the tool flank land. Chipping and brittle fractures were observed at very low and high depth of cut. Adhesion of work piece material followed by plastic deformation and notching was clearly visible at low work piece hardness. The influence of cutting speed, feed rate, depth of cut, and work piece hardness on the progressive tool flank wear, and flank wear rate (VBr-μm/km) in the steady wear region was also analysed.

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Dureja, J. S., V. K. Gupta, V. S. Sharma, and M. Dogra. "Wear mechanisms of TiN-coated CBN tool during finish hard turning of hot tool die steel." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 224, no. 4 (2009): 553–66. http://dx.doi.org/10.1243/09544054jem1664.

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The aim of the present investigation was to identify the wear mechanisms of TiN-coated CBN tools prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed were abrasion wear at low cutting speed, low feed rate, and high workpiece hardness; formation of a transferred layer resulting from tribochemical reactions between constituents of the tool and workpiece material at high speed; and the formation of built-up edges at moderate cutting speed. Hard carbide particles of the work material at higher feed rate severely abraded the tool flank land, resulting in shallow grooves due to the detachment of CBN grains. At greater depth of cut, the built-up edges and transferred layer reduced friction and tool wear. Excessive adhesion of workpiece material followed by plastic deformation and notching were clearly visible at low workpiece hardness (47 HRC). The influence of cutting speed, feed rate, depth of cut, and workpiece hardness on the progressive tool flank wear, i.e. flank wear rate (VBr, μm/mm) in the steady wear region, was also analysed. The flank wear rate was observed to decrease with increase in cutting speed, depth of cut, and workpiece hardness, but after an initial decrease it increased with increase in feed rate.

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Mudzaffar, Raqibah Najwa, Hanani Hani Mohd Khairy, Nur Khairunnisa Mohd Zaki, et al. "Comparative Study on the Performance of ZTA Cutting Tool with the Addition of Different Particle Size of MgO Additive." Materials Science Forum 1010 (September 2020): 181–86. http://dx.doi.org/10.4028/www.scientific.net/msf.1010.181.

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This paper investigated the performance of ZTA cutting tool with the addition of different particle size of MgO additive. Therefore, the objective of this research is to compare the effects of machining parameters on tool wears of ZTA cutting tools added with micro and nanoparticle of MgO. The experiments were conducted using BridgePort-Romi Powerpath CNC machine using a tool holder Sandvik Coromant (CoroTurn CCLNR 164D-4) to hold the cutting tools properly. The parameters are set up as cutting speeds used between range 354 to 472 m/min, feed rate from 0.1 to 0.5 mm/rev with a constant depth of cut of 0.2 mm. Three types of wear were analyzed which are flank wear, crater wear and tool chipping. Flank wear and crater wear images captured using measuring microscope (NIKON MM-400/L) and the crater wear areas are analyzed using MatLab programming software. Tool chipping is observed via SEM (JEOL JSM-5600). The experimental result shows that flank wear and crater wear increase when cutting speed and feed rate increase. ZMN cutting tool shows lower value of flank wear at 0.143 mm and 3.741 mm2 for crater wear than ZMM, 0.321 mm and 3.808 mm2 respectively. On the contrary, cutting speed did not affect the tool chipping severely as feed rate. Moreover, ZMN also shows that the tool breakage occurred severely than ZMM due to the high load on the tool nose.

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Watanabe, Tohru. "A Model-Based Approach to Adaptive Control Optimization in Milling." Journal of Dynamic Systems, Measurement, and Control 108, no. 1 (1986): 56–64. http://dx.doi.org/10.1115/1.3143743.

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An adaptive control optimization system using a model to represent actual physical phenomena in milling is discussed. The model is used for the identification of physical parameters, the calculation of the temperature at the tool edges, and the estimation of the tool wear rate. The shear angle of the shear plane, the flank wear land length of the tool edge, the true contact area at the flank wear land, the radial depth and the axial depth of cut are identified as the physical parameters, the shear stress, and the hardness of the work material from bending moments and torque in the spindle generated by the cutting force. The temperature at the flank wear land is calculated from identified parameters. The tool wear is represented theoretically as the summation of the thermal, mechanical and shock wears. Each wear is calculated from identified parameters and the temperature at the tool edges. Adaptive control experiments to keep the tool-wear rate at a constant value verify that the total system works well. An adaptive control optimization system using the tool-wear rate equation is compared with an adaptive control constraint system using Taylor’s tool life equation in a computer simulation. The simulation shows that adaptive control optimization gives higher cost efficiency than adaptive control constraint when the process parameters vary.

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Xu, Li Fu, Wei Liang Dong, Shu Tao Huang, and Bao Lin Dai. "Experimental Study of Tool Wear during Quasi High Speed Turning Titanium Alloy with Large Cutting Depth." Materials Science Forum 800-801 (July 2014): 548–52. http://dx.doi.org/10.4028/www.scientific.net/msf.800-801.548.

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The wear morphology of rake face and flank face of tool is investigated by turning titanium alloy TC4 with CBN solid tool. It has been observed that the main wear form of rake face and flank face of tool is groove wear. The relation between tool flank wear and cutting speeds, feed rate, and cutting depth obtained from experimental data is given.

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Fatima, Anis, Muhammad Wasif, Aqeel Ahmed, and Saima Yaqoob. "Effect of rake face surface of cutting tool on tool crater wear." Manufacturing Review 10 (2023): 15. http://dx.doi.org/10.1051/mfreview/2023013.

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Tool wear is complex to predict due to the intricate environment of a machining process. However, there are a confrontational effect of tool wear on the machining process in terms of deprived surface finish, reduced dimensional accuracy and increased power consumption. In this study an attempt is made to examine the effect of rake face surface of the cutting tool on tool crater wear. For this, three different types; uncoated, coated and structured rake face cutting tools were used and cutting test were performed of plain carbon steel (AISI/SAE 4140). The cutting speed of 283 m/min, feed rate of 0.1 mm/min and depth of cut of 0.1 were used. Results show, structured rake face of the cutting tool benefitted most in supressing the tool crater wear. Energy-Dispersive X-Ray analysis (EDXA) analysis confirms reduction in iron transfer on tool rake face in case of coated and structured cutting tool. Micro − hardness test was also performed and the values in case of coated and structured cutting tool was found to be suffice. This study can be a benefit for cutting difficult to cut material where crater wear formation is unavoidable.

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Burhanuddin, Yanuar, Che Hassan Che Haron, and Jaharah A. Ghani. "The Effect of Tool Edge Geometry on Tool Performance and Surface Integrity in Turning Ti-6Al-4V Alloys." Advanced Materials Research 264-265 (June 2011): 1211–21. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1211.

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This paper focuses on the influence of cutting tool edge geometry, cutting speed and feed rate on the tool performance and workpiece’s surface integrity in dry turning of Ti-6Al-4V alloy using PCBN inserts. The parameters evaluated are tool life, wear rate, wear mechanisms, surface roughness and subsurface microstructure alterations. The rate of wear growth of the insert was assessed by progressive flank wear using optical microscope by taking photographs after certain length of cut. The wear mechanism at the end of tool life was investigated in detail using scanning electron microscope (SEM) and EDAX analysis. The results show, by increasing the cutting speed and feed rate resulted in tool life reduction. Cutting with honed edge insert at cutting speed of 180 m/min has shown very little wear, even after 20 min of cutting. The honed insert proved less sensitive to increases in feed rate than the chamfered insert. In general the honed insert showed a significant improvement in tool life. All inserts failed due to attrition wear and adhesion. No flank notch wear was observed, but some crater wear occurred at the chamfer land. Microstructure alteration was not found when machining using the different edge geometry. In these trials, the subsurface micro structural deformations in the direction of cutting were deformed grain boundaries and elongation of grains. Chip smearing and debris on the surface was also found.

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Wada, Tadahiro, and Hiroyuki Hanyu. "Wear Mechanism of Multilayer AlCrWN/AlCrWSiN-coatings on Cemented Carbide Tools Prepared by Arc Ion Plating in Dry Cutting of Hardened Sintered Steel." MATEC Web of Conferences 303 (2019): 06003. http://dx.doi.org/10.1051/matecconf/201930306003.

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In this study, to clarify the wear mechanism of the multilayer AlCrWN/AlCrWSiN-coated tool in cutting of hardened sintered steel, the rate of wear in the cutting of hardened sintered steel using three types of coated tools was investigated. The Type I tool had a single layer (Al60, Cr25, W15)N coating film, the Type II tool had a single layer (Al53, Cr23, W14, Si10)N coating film and the Type III tool had a multilayer (Al60, Cr25, W15)N/(Al53, Cr23, W14, Si10)N-coating film. Scanning electron microscope (SEM) observation and electron dispersive X-ray spectrometry (EDS) mapping analysis of the abraded surface of the coating film were performed. The following results were obtained: 1) The wear rate of the Type III tool was the slowest. 2) The area of the worn surface on the rake face “S” and the contact length between the rake face and the chip “D” were measured. Comparing the three types of coated tools, both the “S” and the “D” of Type I tool were the smallest, and those of Type II tool were the largest. 3) The main wear mechanism of Type II and Type III tool showed abrasive wear. However, the main wear mechanism of the Type I tool was both abrasive wear and adhesion wear. 4) The critical scratch load of the Type I tool, 81 N, was lower than that of the Type II or the Type III tool, over 130 N. Therefore, comparing the Type I and Type III tools, due to the wear mechanism of the Type 1 tool being both abrasive wear and adhesion wear, the wear rate of the Type I tool, which has the lower critical scratch load, was slower.

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Hosseinkhani, Keyvan, and Eu-Gene Ng. "A Unique Methodology for Tool Life Prediction in Machining." Journal of Manufacturing and Materials Processing 4, no. 1 (2020): 16. http://dx.doi.org/10.3390/jmmp4010016.

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In this paper, a unique approach for estimating tool life using a hybrid finite element method coupled with empirical wear rate equation is presented. In the proposed approach, the computational time was significantly reduced when compared to nodal movement technique. However, to adopt such an approach, the angle between tool’s rake and flank faces must be constant through the process and at least two cutting experiments need to be performed for empirical model calibration. It is also important to predict the sliding velocity along the tool/flank face interface accurately when using Usui’s model to predict the tool wear rate. Model validations showed that when the sliding velocity was assumed to be equivalent to the cutting speed, poor agreement between the predicted and measured wear rate and tool life was observed, especially at low cutting speed. Furthermore, a new empirical model to predict tool wear rate in the initial or break-in period as a function of Von Mises stress field was developed. Experimental validation shows that the newly developed model substantially improved the initial tool wear rate in terms of trend and magnitude.

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Navuluri Padma Sravya, R. Manimegalai, R. Rajeswari, M. Gowtham, R. S. Achsah, and S. Naveen. "Enhancing Surface Quality and Tool Longevity in EDM of D2 Steel Using Copper Composite Tools." Journal of Environmental Nanotechnology 13, no. 3 (2024): 321–31. http://dx.doi.org/10.13074/jent.2024.09.243803.

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Hard material machining and die manufacture are the main applications for electrical discharge machining (EDM). For EDM, conventional electrode materials include graphite, steel, brass, pure copper, and alloys based on copper. Unfortunately, excessive tool wear is a common problem with these materials, which raises the cost of machining. In this investigation, hardened D2 steel was machined using a composite tool made of 90% copper and 10% silicon carbide. The powder metallurgy method was used to create the composite tool. Surface roughness (SR) and electrode wear rate (EWR) were compared to a number of process variables. For experimentation, a response surface methodology based on CCD design in design of experts software was used. SR and electrode wear rate models were created using the CCD approach. Utilizing analysis of variance, the most important factors and their effects on EWR and SR were determined. The lowest tool wear rate of 0.39 gm/min is achieved with a current of 5 Amps, a pulse duration of 100 µs, and a pulse interval of 10 µs with an R2 of 0.9957, which accounts for 99.57% of the variability, the tool wear rate model fits the data very well and obtained lowest surface roughness of 2.8 µm.

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Ji Cai, Kuai, and Fei Hu Zhang. "Cutting Mechanism and Model for Cutting Al/SiCp Composites." Advanced Materials Research 189-193 (February 2011): 4087–91. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.4087.

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Al/SiCp composite material is rapidly advanced due to its applications to weapon, military, aeronautics and astronautics. In some cases, fields of research are stagnating for its difficulty in material processing. In this study, we are particularly concerned about the cutting mechanism of Al/SiCp through modeling and simulations on wear rate of the tools. These simulations of tool wear rate and cutting mechanism of Al/SiCp are proved by cutting tests on Al/SiCp with nanocemented carbide tool WC-7Co and common cemented carbide tool YG8. A detailed investigation suggests that the cutting instinct of Al/SiCp is of interrupted cutting process. And the grain loss, less tipping and blade fracture during tool wear results from high frequency intermittent shock by SiC grain. The wear behavior on the tool flank is mainly of grain loss. However, the wear behavior of the rake face is not only of grain loss, but also abrasive wear of WC grain by SiC grain. It is conclusively demonstrated that the model of tool wear rate is sufficient for revolution characterization of tool wear rate on grain size, volume fraction of reinforcement, and also significantly important to prove the interrupted cutting process mechanism of Al/SiCp.

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Laakso, Sampsa V. A., and Daniel Johansson. "There is logic in logit – including wear rate in Colding’s tool wear model." Procedia Manufacturing 38 (2019): 1066–73. http://dx.doi.org/10.1016/j.promfg.2020.01.194.

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Wei, Weihua, Yingli Li, Tongming Xue, et al. "Tool wear during high-speed milling of wood-plastic composites." BioResources 14, no. 4 (2019): 8678–88. http://dx.doi.org/10.15376/biores.14.4.8678-8688.

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A high-speed milling test was performed with a self-developed wood-plastic composite using uncoated and coated carbide cutting tools. The nose width was used to represent the tool wear. An advanced tool measurement system was adopted to measure the wear of each tool. The influence of some cutting parameters, including spindle speed, feed rate, axial cutting depth, and radial cutting depth, on the tool wear was analyzed using a single factor test method. Scanning electron microscopy was used to observe the wear morphology on the rake and clearance face of the tool before and after the tool was worn. The results showed that the tool nose width increased with increased axial cutting depths or spindle speeds, while the radial depth under the condition of the same cutting length decreased with an increase in the feed rate. Moreover, the main form of tool wear was abrasive wear and coating peel-off when the wood-plastic composites were machined with high-speed milling.

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Matsumura, Takashi, Shoichi Tamura, and Aiso Toshiharu. "Analysis of Tool Wear Rate during a Rotation of Cutter in Fly Cutting." Defect and Diffusion Forum 441 (March 26, 2025): 11–18. https://doi.org/10.4028/p-ejstm4.

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Tool life is recognized as a critical factor in finishing a fine surface as well as high machining accuracy in cutting operation. The tool wear progress, therefore, should be evaluated in cutting simulation before the operation. This paper presents an analysis of tool wear rate during a rotation of tool in fly cutting as a manner of gear machining. The distribution of tool wear rate is analyzed with the stress and the temperature on the rake face based on a tool wear characteristic equation. The cutting force is estimated in a chip flow model, which piles up the orthogonal cuttings in the plane containing the cutting and the chip flow directions. The chip flow direction is determined to minimize the cutting energy. Then, the cutting temperature is analyzed numerically in the finite volume method, where the mechanical energy is converted to the heat generation in the shear zone and the rake face. In the fly cutting, the stress and temperature change with the uncut chip thickness and the tool-chip contact area during a rotation. Therefore, the instantaneous tool wear rates are analyzed for the rotation angles by the stress and the temperature distributions. This paper demonstrates an example of the tool wear analysis in cutting processes of a carbon steel. A cutting test was conducted to identify the force model with the orthogonal cutting data used in the analysis. Then, the temperature and tool wear distributions on the rake face are analyzed with the uncut chip thicknesses and the tool-chip contact areas.

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Davoudinejad, Ali, M. Y. Noordin, Danial Ghodsiyeh, Sina Alizadeh Ashrafi, and Mohsen Marani Barzani. "Effect of Tool Wear on Tool Life and Surface Finish when Machining DF-3 Hardened Tool Steel." Applied Mechanics and Materials 315 (April 2013): 241–45. http://dx.doi.org/10.4028/www.scientific.net/amm.315.241.

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Hard turning is a dominant machining operation performed on hardened materials using single-point cutting tools. In recent years, hard turning operation has become more and more capable with respect to various machinability criteria. This work deals with machinability of hardened DF-3 tool steel with 55 ±1 HRC hardness at various cutting conditions in terms of tool life, tool wear mechanism and surface roughness. Continuous dry turning tests were carried out using coated, mixed ceramic insert with honed edge geometry. Two different cutting speeds, 100 and 210 m/min, and feed rate values of 0.05, 0.125 and 0.2 mm/rev were used with a 0.2 mm constant depth of cut for all tests. Additionally scanning electron microscope (SEM) was employed to clarify the different types of wear. As far as tool life was concerned, best result was achieved at lowest cutting condition whereas surface roughness values decreased when operating at higher cutting speed and lower feed rate. Additionally maximum volume of material removed is obtained at low cutting speed and high feed rate. Dominant wear mechanism observed during the experiments were flank and crater wear which is mainly caused by abrasive action of the hard workpiece material with the ceramic cutting tools.

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Denkena, Berend, Marc-André Dittrich, and Julia Mainka. "Simulation-based feed rate adaptation considering tool wear condition." Procedia Manufacturing 52 (2020): 133–37. http://dx.doi.org/10.1016/j.promfg.2020.11.024.

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Feng, Yixuan, Fu-Chuan Hsu, Yu-Ting Lu, et al. "Tool wear rate prediction in ultrasonic vibration-assisted milling." Machining Science and Technology 24, no. 5 (2020): 758–80. http://dx.doi.org/10.1080/10910344.2020.1752240.

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Jahan, Muhammad Pervej, Jianfeng Ma, Craig Hanson, and Greg K. Arbuckle. "Tool wear and resulting surface finish during micro slot milling of polycarbonates using uncoated and coated carbide tools." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234, no. 1-2 (2019): 52–65. http://dx.doi.org/10.1177/0954405419862479.

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A growing application of polycarbonates is in the microfluidic disks and DNA detection devices, where surface finish of the micro-channels plays an important role. This study intends to investigate the tool wear and surface finish generated during micro slot milling of polycarbonate using uncoated, TiN-coated, and TiAlN-coated tungsten carbide tools. The effects of tool coating and the machining parameters on the possible reduction of tool wear and improvement of surface finish were investigated. It was found that with careful selection of cutting parameters and tool coating, micro-channels with smoother surface finish, minimum burrs around the edges, and controlled tool wear can be obtained using micro-milling. A combination of medium range of depth of cut and feed rate was found to improve the surface finish in polycarbonates, as well as minimize the tool wear. The TiAlN tool coating was found to only be effective in reducing tool wear without much effect on the machined surface. The adhesion was found to be the most dominating tool wear mechanism in uncoated carbide tool, followed by cutting edge chipping and tool nose’s plastic failure. The adhesion wear was found to be reduced in coated tools, especially in TiAlN-coated tools, although delamination wear started to dominate in the coated tools when higher feed rate and depth of cut were used. Both lower and higher of depths of cut were found to generate higher tool wear and leave traces of tool marks on the machined surface.

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BEZJAZYCHNYI, Vyacheslav F., and Vladislav V. PLESKUN. "THE EFFECT OF CUTTING TOOL WEAR ON THE RATE OF CORROSION WEAR OF A MACHINED MATERIAL." Tribologia 289, no. 1 (2020): 5–11. http://dx.doi.org/10.5604/01.3001.0014.0833.

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A possible variant for calculated estimation of the degree of the impact of the cutting tool wear on the value of the part’s surface layer wear obtained during processing with the edge tool, due to atmospheric corrosion, is presented. The feature is the evaluation of the wear rate and its numerical value depending on the tool wear, roughness parameters of the work piece surface, and the degree of cold hardening of the surface layer, as well as parameters of the technological machining conditions (cutting conditions, geometry of the tool cutting part, properties of the machined and the tool materials).

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Teimouri, Reza, and Hamid Baseri. "Study of Tool Wear and Overcut in EDM Process with Rotary Tool and Magnetic Field." Advances in Tribology 2012 (2012): 1–8. http://dx.doi.org/10.1155/2012/895918.

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Tool wear and workpiece overcut have been studied in electrical discharge machining process with rotational external magnetic field and rotational electrode. Experiments have been divided to three main regimes, namely, low-energy regime, middle-energy regime, and high-energy regime. The influence of process parameters were investigated on electrode wear rate and overcut. Results indicate that applying a magnetic field around the machining gap increases the electrode wear rate and overcut. Also, rotation of the tool has negative effect on overcut.

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Suwanda, Totok, Nur Aji Wijayanto, and Nur Ardiyansyah. "Comparison of Tool Wear Rate of Insert Lathe TNMG160404-MA and TNMG160404-TF." Jurnal Sains dan Teknologi Industri 21, no. 1 (2023): 5. http://dx.doi.org/10.24014/sitekin.v20i2.22824.

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Lathe machines are used to work on cylindrical objects. Tool wear is often a problem in the turning process and impacts the results of the machining process. The research aims to compare lathe insert tool wear levels TNMG160404-MA and TNMG160404-TF. The research used the experimental method directly using a lathe with variable machining on feeding (f) 0.04 mm/rev and 0.08 mm/rev, spindle (n) 540 rpm, and depth of cut (a) 4 mm. Tool wear was measured using an optical microscope by measuring the maximum edge wear on the tool (VBmax) and to determine the significance of tool wear using statistical analysis. The results showed wear level insert tool of TNMG160404-MA at a feeding of 0.04 mm/put an average of VBmax = 85.00(μm) and a feeding of 0.08 mm/put VBmax = 63.23(μm). TNMG160404-TF insert tool wear at 0.04 mm/put feed VBmax = 76.18(μm) and 0.08 mm/put feed VBmax = 58.43(μm). On a feeding, 0.08 mm/put motion, the standard deviation (s) of the TNMG160404-MA insert tool is 16.2, and the standard deviation (s) of the TNMG160404-TF insert tool is 17.8. On a feeding of 0.08 mm/rev, the results of t-count = 0.630 and t-table = 2.101, so t-count < t-table (0.630 < 2.101), the statistical analysis results using the t-test showed no significant difference in the level of wear of the two types insert tools.

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Wang, Yu, Yuan Sheng Zhai, Fu Gang Yan, and Xian Li Liu. "Predicted Rake Face Wear of PCBN Cutting Tools in High-Speed Precision Hard Cutting." Advanced Materials Research 69-70 (May 2009): 163–66. http://dx.doi.org/10.4028/www.scientific.net/amr.69-70.163.

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PCBN cutting tool’s wear in high speed precision reaches tool wear criterion will cause cutting force and cutting temperature increase clearly, chip color change or melt. Even vibration in cutting will influence dimension accuracy and surface quality of workpiece. It is very useful to establish model by FEM simulation of tool wear predicted. The influence of tool wear in cutting conditions will assurance of machining quality and efficiency, decreasing rate of product cost. PCBN cutting tool’s wear is simulated by FEM software Deform 2D, rake face wear state can be analysed by the influence of tools geometric parameters and cutting parameters tool wear.

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Liu, Ju Dong, Dong Ming Yu, Jia Wei Jin, Xian Zhen Ye, and Xiao Fan Yang. "Orthogonal Experimental Study on Tool Wear in Machining CFRP with CVD Diamond Film Coated Tool." Advanced Materials Research 1015 (August 2014): 10–13. http://dx.doi.org/10.4028/www.scientific.net/amr.1015.10.

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The influence of milling parameters on flank wear is investigated through the orthogonal experiment of milling carbon fiber reinforced plastics (CFRP) with CVD diamond film coated tools and cemented carbide tools. The results show that: the interaction between spindle speed and feed rate has significant impact on the flank wear of CVD diamond film coated tool, and the influence of factors to flank wear decrease in the order: interaction > feed rate > spindle speed > cutting width. When spindle speed of n is 5000r/min, feed rate of vf is 100mm/min, cutting width of ap is 1mm, the lifetime of CVD diamond film coated tool and the processing quality of CFRP parts can be improved.

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Yin, Ganggang, Jianyun Shen, Ze Wu, Xian Wu, and Feng Jiang. "Experimental Investigation on the Machinability of PCBN Chamfered Tool in Dry Turning of Gray Cast Iron." Processes 10, no. 8 (2022): 1547. http://dx.doi.org/10.3390/pr10081547.

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Polycrystalline cubic boron nitride (PCBN) tools are widely used for hard machining of various ferrous materials. The edge structure of the PCBN cutting tool greatly affects the machining performance. In this paper, dry turning experiments were conducted on gray cast iron with a PCBN chamfered tool. Both the cutting temperature and the cutting force were measured, and then the surface quality and tool wear mechanisms were analyzed in detail. It was found that the cutting temperature and cutting force increased with the increase in feed rate, depth of cut, and cutting speed. The surface roughness firstly decreased, and then increased with an increase in feed rate. The minimum surface roughness was obtained with a feed rate of 0.15 mm/r which exceeded the tool chamfer width. The PCBN tool wear mode was mainly micro notches on the rake face and micro chipping on the tool chamfer, while the adhesion wear mechanism was the main tool wear mechanism.

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Ráczkövi, László. "Wear Rate of CBN Cutting Tool in Hard Turning of 100Cr6 Bearing Steel." Key Engineering Materials 581 (October 2013): 50–54. http://dx.doi.org/10.4028/www.scientific.net/kem.581.50.

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The examination of wear and tool life of CBN cutting tools which are used for hard turning is a emphasized research theme, since the significant proportion of cost of machining associated with cutting tool. In this article we examined the wear of low CBN content cutting tool in case of hard turning of 100Cr6 bearing steel (HRC=62±2). The experiments were carried out with constant depth of cut and feed rate at three different cutting speeds. The flank wear of CBN inserts were measured after predetermined number of passes. The measured flank wear values were described as a function of cutting time and the calculated wear rate as a function of flank wear.The average wear rate were shown at three different cutting speeds.

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Zheng, Guang Ming, Jun Zhao, Xin Yu Song, Cao Qing Yan, and Yue En Li. "Ultra High Speed Turning of Inconel 718 with Sialon Ceramic Tools." Advanced Materials Research 126-128 (August 2010): 653–57. http://dx.doi.org/10.4028/www.scientific.net/amr.126-128.653.

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This paper explores the wear mechanisms of a Sialon ceramic tool in ultra high speed turning of Nickel-based alloy Inconel 718. Microstructures of the chips are also investigated. Stereo optical microscope and scanning electron microscope (SEM) are employed to observe worn surfaces of the tool produced by various wear mechanisms and morphological features of chips. In addition, the elemental compositions of wear products are evaluated by energy-dispersive X-ray spectroscopy (EDS). As a result of the study, wear mechanisms identified in the machining tests involve adhesive wear and abrasive wear. At the initial stage of cutting process, crater wear and flank wear are the main wear patterns. At the rapid wear stage, the SEM and EDS results showed that the adhered elements of Inconel 718 alloy on the tool rake face such as Ni, Fe and Cr accelerated the tool wear rate. Meanwhile, it was found that the chip morphology was serrated type under ultra high speed cutting condition, furthermore, the tendency of serration of the chip increased with the increase in cutting speed and feed rate.

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Zhang, Zheng Mei, Jin Sheng Zhang, Sheng Gao, Cheng Rui Lu, and Chun Ying Zheng. "Experimental Study on Relation between Tool Wear and Grinding Force for Shaping Diamond Tool." Advanced Materials Research 97-101 (March 2010): 1925–28. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.1925.

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Based on orthogonal experiment design, a study on the one-fourth arc special-shaped surface of Lord Red granite was conducted, the relationship between cutting speed, feed rate and cutting depth with tool wear rate and grinding force were analyzed. The research shows that tool wear rate and grinding force are basically reduced with the increase of cutting speed and aggrandized with the increase of feed rate and cutting depth. By regression analysis the empirical formulas of grinding forces are concluded, it is the theoretical foundation for on-line monitoring grinding force to optimize the processing parameters for machining irregular surface of granite.

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Erry, Yulian T. Adesta, Riza Muhammad, and Avicenna. "Content Comparative Investigation on Tool Wear During End Milling of AISI H13 Steel with Different Tool Path Strategies." Bulletin of Electrical Engineering and Informatics 6, no. 4 (2017): 327–33. https://doi.org/10.11591/eei.v6i4.852.

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Tool wear prediction plays a significant role in machining industry for proper planning and control machining parameters and optimization of cutting conditions. This paper aims to investigate the effect of tool path strategies that are contour-in and zigzag tool path strategies applied on tool wear during pocket milling process. The experiments were carried out on CNC vertical machining centre by involving PVD coated carbide inserts. Cutting speed, feed rate and depth of cut were set to vary. In an experiment with three factors at three levels, Response Surface Method (RSM) design of experiment with a standard called Central Composite Design (CCD) was employed. Results obtained indicate that tool wear increases significantly at higher range of feed per tooth compared to cutting speed and depth of cut. This result of this experimental work is then proven statistically by developing empirical model. The prediction model for the response variable of tool wear for contour-in strategy developed in this research shows a good agreement with experimental work.

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Ibrahim, Mohd Rasidi, Tharmaraj Sreedharan, Nurul Aisyah Fadhlul Hadi, et al. "The Effect of Cutting Speed and Feed Rate on Surface Roughness and Tool Wear when Machining Machining D2 Steel." Materials Science Forum 909 (November 2017): 80–85. http://dx.doi.org/10.4028/www.scientific.net/msf.909.80.

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Machining parameters is a main aspect in performing turning operations using lathe machines. Cutting parameters such as cutting speed, feed rate and depth of cut gives big influence on the dynamic behavior of the machining system. In machining parts, surface quality and tool wear are the most crucial customer requirements. This is because the major indication of surface quality on machined part is the surface roughness and the value of tool wear. Hence, to improve the surface roughness and minimize the forming of tool wear, the optimum feed rate and cutting speed will be determined. The input parameter such as cutting speed, feed rate and depth of cut always influence the tool wear, surface roughness, cutting force, cutting temperature, tool life and dimensional accuracy. The D2 steel was being investigated from the perspective of the effect of cutting speed and feed rate on its surface roughness and tool wear. The results show that cutting speed is the main parameter which affects the surface roughness where the most optimum parameter would be at cutting speed of 173, 231 and 288 m/min with feed rate of 0.15 mm/rev. The tool wear strongly affected by feed rate where at 0.15 mm/rev the tool wear value is the lowest. The combination of high cutting speed and low feed rate was the best parameter to achieve smooth surface roughness.

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Jia, Peng, M. Zhou, and S. N. Huang. "Progressive Tool Wear in Diamond Cutting of Glass Soda-Lime." Key Engineering Materials 499 (January 2012): 138–43. http://dx.doi.org/10.4028/www.scientific.net/kem.499.138.

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For the technology of diamond cutting of optical glass, the high tool wear rate is a main reason for hindering the practical application of this technology. Minimizing the tool wear is of great significance in order to achieve the satisfactory surface quality and dimensional accuracy. For in depth understanding of the tool wear mechanisms, experiments of diamond turning with cutting distance increased gradually was carried out on soda-lime glass in this work. Experimental results indicate that the flank wear was predominant in diamond cutting glass and the flank wear land was characterized by micro-grooves, some smooth crater on the rake face was also seen. The mainly mechanisms inducing tool wear in diamond cutting of glass are diffusion, mechanical friction, thermo-chemical action and abrasive wear.

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Yazid, M. Z. A., C. H. Che Hassan, A. G. Jaharah, A. I. Gusri, and M. S. Ahmad Yasir. "Tool Wear of PVD Coated Carbide Tool when Finish Turning Inconel 718 under High Speed Machining." Advanced Materials Research 129-131 (August 2010): 1004–8. http://dx.doi.org/10.4028/www.scientific.net/amr.129-131.1004.

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This paper reports the results of an experimental works, where Inconel 718, a highly corrosive resistant, nickel-based super alloy, was finish-turning under high speed conditions. The machining processes were carried out at three different cutting conditions (DRY, MQL 50 ml/h and MQL 100 ml/h), three levels of cutting speed (Vc=90, 120 and 150 m/min), two levels of feed rate (f=0.10 and 0.15 mm/rev) and two levels of cutting depth (d=0.30 and 0.50 mm). The tool wear and flank wear progression were monitored, measured and recorded progressively at various time intervals. The experiments indicated that MQL condition performs better than dry condition in term of tool life. Most of the tool failures during machining were due to gradual failure where abrasive and notching wear on the flank face was the dominant followed by, fracture on the flank edge and nose radius. Tool failure due to crater wear was not significant. Wear mechanism such as abrasive and adhesion were observed on the flank face and diffusion wear was observed on the rake face.

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Peng, Rui Tao, Jing Li, Xin Zi Tang, and Zhuan Zhou. "Simulation of Tool Wear in Prestressed Cutting Superalloys." Materials Science Forum 836-837 (January 2016): 402–7. http://dx.doi.org/10.4028/www.scientific.net/msf.836-837.402.

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In high speed machining superalloys processes, tool wear is strongly influenced by the cutting temperature and contact stresses. Finite element analysis of machining can be used as a supplementary to the physical experiment, this paper provides investigations in 2D and 3D finite element modeling and simulation of prestressed cutting for GH4169 superalloy, a tool wear model for the specified tool and workpiece pair is developed based on the Usui's wear model, furthermore, tool temperature, wear rate and nodal displacement on the face of tool in prestressed cutting of superalloy is analyzed under various prestress condition and cutting parameters, and Python language is adopted to modify the Abaqus code used to allow tool wear calculation and tool geometry updating. The results of the simulation indicate that the tool wear rate increases with the increase of cutting time, and the influence of the prestress to tool wear in prestressed cutting process of shaft part is unremarkable.

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Chendri, Johan*. "WEAR ANALYSIS TOOL CARBIDE INSERTS DUE TO DRY MACHINING STAINLESS STEEL." INTERNATIONAL JOURNAL OF RESEARCH SCIENCE & MANAGEMENT 4, no. 12 (2017): 23–27. https://doi.org/10.5281/zenodo.1097144.

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Turning is a machining process that aims to shape the material in particular cylindrical. In turning there are a number of problems that arise and may interfere with the process of production, one of which is a tool wear. This research examines the hardness and wear of tools by using tool Al2O3 + TiO2 and tool TiO2. Experimental method is the method used in this study where rockwell hardness testing use testing and measurement of edge wear toolmaker microscope using a measuring instrument. Stainless steel is the material used in the machining process. Hardness testing results obtained to tool Al2O3 + TiO2 is 87,82 HRC and tool TiO2 is 87,52 HRC. Measurement of the average flank wear tools Al2O3 + TiO2 is 0,040 VB and tools TiO2 is 0,016 VB. Cutting speed significant effect on tool wear on turning the results of stainless steel grade 301, depth of cut and feed rate had no significant effect. But simultaneously, all three of these parameters significantly affect tool wear.

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Cappellini, Cristian, and Andrea Abeni. "Development and implementation of crater and flank tool wear model for hard turning simulations." International Journal of Advanced Manufacturing Technology 120, no. 3-4 (2022): 2055–73. http://dx.doi.org/10.1007/s00170-022-08885-y.

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AbstractThis paper concerns the tool wear in hard turning of AISI 52100 hardened steel by means of PCBN tools. The purposes of this work are the development of a tool wear model and its implementation in a FEM-based procedure for predicting crater and flank wear progression during machining operations for studying the influence of tool wear on the process in terms of tool geometry modifications and stress variation on the tool. The developed tool wear model, able to update the geometry of the worn tool as a function of the wear rate, has been implemented in the utilized Deform 2D FEM software. This new analytical model differs from the already proposed methods of existing research, since it concerns both crater and flank wear evaluation. The validation of the model has been achieved by the comparison between experimental and simulated wear parameters. For doing this, an extended experimental campaign has been accomplished. The comparison results have shown good agreement. Once validated, the FEM strategy has been utilized for examining the influence of tool wear on the effective rake angle and the related tool stresses, individuating the excessive positive rake angle value as the final tool breakage mechanism.

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Wu, Jinxing, Lin He, Yanying Wu, et al. "Enhancing Wear Resistance and Cutting Performance of a Long-Life Micro-Groove Tool in Turning AISI 201." Coatings 11, no. 12 (2021): 1515. http://dx.doi.org/10.3390/coatings11121515.

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Tool-chip friction increases cutting temperature, aggravates tool wear, and shortens the service life of cutting tools. A micro-groove design of the rake face can improve the wear performance of the tool. In this study, we used the finite element simulation “Deform” to obtain the temperature field distribution of the tool rake face. The size of the micro-groove was determined by selecting a suitable temperature field combined with the characteristics of tool–chip flow in the cutting process, and the tool was prepared using powder metallurgy. The three-direction cutting forces and tool tip temperature were obtained by a cutting test. Compared with the original turning tool, the cutting force and cutting temperature of the micro-groove tool were reduced by more than 20%, the friction coefficient was reduced by more than 14%, the sliding energy was reduced and the shear energy was greatly decreased. According to the analysis of tool wear by SEM (scanning electron microscope) and EDS (energy dispersive X-ray spectroscopy), the crater wear, adhesive wear and oxidation wear of the micro-groove tool were lower than those of the original turning tool. In particular, the change in the crater wear area on the rake face of the original tool and the micro-groove tool was consistent with the cutting temperature and the wear width of the flank face. On the whole, the crater wear area and the change rate of the crater wear area of the micro-groove tool were smaller. Due to the proper microgroove structure of the rake face, the tool-chip contact area decreased, and the second rake angle of the tool became larger. Hence, the tool-chip friction, cutting forces, cutting energy consumption were reduced, tool wear was improved, and the service life of the micro-groove tool was five times longer than that of the original tool.

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Zawawi, Mohd Zairulnizam, Mohd Ali Hanafiah Shaharudin, and Ahmad Rosli Abdul Manaf. "Influences of Varying Combination of Feed Rate and Depth of Cut to Tool Wear Rate and Surface Roughness: High Speed Machining Technique in Non-High Speed Milling Machine." Advanced Materials Research 903 (February 2014): 194–99. http://dx.doi.org/10.4028/www.scientific.net/amr.903.194.

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Machining technique using high spindle speed, high feed rate and shallow depth of cut utilize in High Speed Milling (HSM) machines offer several benefits such as increase of productivity, elimination of secondary and semi-finishing process, reduce tool load and small chips produced. By adjusting some of the machining parameters, non-HSM machine having lower spindle speed and feed rate could also take advantages some of the benefits mentioned above when applying the HSM technique. This experiment investigate the effects of varying combination of depth of cut and feed rate to tool wear rate and surface roughness during end milling of Aluminum and P20 tool steel in dry condition. The criterion for tool wear before it gets rejected is based on maximum flank wear, Vb of 0.6mm. Material removal rate, spindle speed and radial depth of cut are constant in this experiment. After preliminary machining trials, the combination starts with depth of cut of 2mm and feed rate of 45mm/min until the smallest depth of cut and highest feed rate of 0.03mm and 3000mm/min respectively. The obtained result shows that for both materials, feed rate significantly influences the surface roughness value while depth of cut does not as the surface roughness value keep increasing with the increase of feed rate and decreasing depth of cut. Whereas, tool wear rate almost remain unchanged indicates that material removal rate strongly contribute the wear rate. With no significant tool wear rate, this study demonstrates that HSM technique is possible to be applied in non-HSM machine with extra benefits of eliminating semi-finishing operation, reducing tool load for finishing, machining without coolant and producing smaller chip for ease of cleaning.

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Uysal, Alper, and Erhan Altan. "Experimental investigation of a slip-line field model for a worn cutting tool." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 228, no. 8 (2013): 1398–404. http://dx.doi.org/10.1177/0954406213507917.

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In this study, the slip-line field model developed for orthogonal machining with a worn cutting tool was experimentally investigated. Minimum and maximum values of five slip-line angles ( θ1, θ2, δ2, η and ψ) were calculated. The friction forces that were caused by flank wear land, chip up-curl radii and chip thicknesses were calculated by solving the model. It was specified that the friction force increased with increase in flank wear rate and uncut chip thickness and it decreased a little with increase in cutting speed and rake angle. The chip up-curl radius increased with increase in flank wear rate and it decreased with increase in uncut chip thickness. The chip thickness increased with increase in flank wear rate and uncut chip thickness. Besides, the chip thickness increased with increase in rake angle and it decreased with increase in cutting speed.

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45

Xu, Dao Chun, Ping Fa Feng, Ding Wen Yu, and Zhi Jun Wu. "Experimental Study on Chip Shape and Tool Wear of High-Speed and Micro-Feed Cutting." Key Engineering Materials 431-432 (March 2010): 479–82. http://dx.doi.org/10.4028/www.scientific.net/kem.431-432.479.

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With increasing spindle speed the cutting will be easy to enter into micro-feed cutting region. In the paper, the chip thickness and shape of high-speed and micro-feed cutting was researched in orthogonal milling. The cutting times in different fz was analyzed. We calculate the effective rake angle, friction angle and shear angle Furthermore, we measure cutting edge arc wear and tool flank wear of micro-feed cutting. Shown as the research results, the phenomenon of empty cutting and pure extrusion is very obvious as the feed rate per tooth is lower than 0.011mm/z. As the feed rate per tooth is lower than 0.005mm/z, the tool wear form is mainly cutting edge arc wear. As fz achieves 0.015mm/z, tool wear will decrease obviously and the tool appears the self-sharpening phenomenon.

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Jatti, Vijaykumar S., and T. P. Singh. "Optimization of Tool Wear Rate during Electro Discharge Machining of NiTi Alloys Using Taguchi Method." Applied Mechanics and Materials 787 (August 2015): 260–64. http://dx.doi.org/10.4028/www.scientific.net/amm.787.260.

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NiTi alloys are advance materials which possess superior properties such as pseudoelasticity, shape memory effect, high wear resistance, high corrosion resistance and high strength. NiTi alloys causes serious tool wear, hardening of the machined surface and poor surface finish. Electro discharge machining (EDM) is an unconventional machining process which demonstrates high capability to machine NiTi alloys. Present work emphasis on investigating the effect of EDM process parameters on the tool wear rate. Gap current, pulse on time and pulse off time were considered at three levels as input process parameters along with electrical conductivity of workpiece and tool electrode at two levels. Taguchi L36 (22 x 33) mixed orthogonal array was utilized to design the experimental plan. Based on the statistical analysis at 95% confidence level it was found that tool electrical conductivity, gap current and pulse on time are the most significant factors that influence the tool wear rate. At optimal setting of parameters the predicted value of tool wear rate obtained was 0.00811 mm3/min.

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Udupi, Sathish Rao, and Lewlyn Lester Raj Rodrigues. "Detecting Safety Zone Drill Process Parameters for Uncoated HSS Twist Drill in Machining GFRP Composites by Integrating Wear Rate and Wear Transition Mapping." Indian Journal of Materials Science 2016 (July 11, 2016): 1–8. http://dx.doi.org/10.1155/2016/9380583.

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The previous research investigations informed that the tool wear of any machining operation could be minimized by controlling the machining factors such as speed, feed, geometry, and type of cutting tool. Hence the present research paper aims at controlling the process parameters to minimize the drill tool wear, during the machining of Glass Fiber Reinforced Polymer (GFRP) composites. Experiments were carried out to find the tool wear rate and a wear mechanism map of uncoated High Speed Steel (HSS) drill of 10 mm diameter was developed for the drilling of GFRP composite laminates. The surface micrograph images on the drill land surface displayed dominant wear mechanisms induced on HSS drill during machining of GFRP and they were found to be adhesive wear, adhesive and abrasive wear, abrasive wear, and diffusion and fatigue wear. A “safety wear zone” was identified on the wear mechanism map, where the minimum tool wear of the HSS drill occurs. From the safety zone boundaries, it was inferred that the drill spindle speed should be set between 1200 and 1590 rpm and feed rate must be set within a range of 0.10–0.16 mm/rev for GFRP work and HSS tool combination to enhance the service life of 10 mm HSS drills and to minimize the tool wear.

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Harto, Budi, Bobby Umroh, and Darianto Darianto. "Study on the CBN Tool Wear Mechanism on Dry High-Rate Turning Process for AISI 4140." JOURNAL OF MECHANICAL ENGINEERING, MANUFACTURES, MATERIALS AND ENERGY 2, no. 1 (2018): 20. http://dx.doi.org/10.31289/jmemme.v2i1.1654.

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This study aims to investigate tools wear and wear mechanisms when machining high-rate extreme minimum lathe AISI 4140 material in hard and dry cutting conditions. Cutting tool made from CBN CB7015 Sandvik Coromant production is used for turning of AISI 4140 steel in order to obtain the failure mode of tool and the wear mechanism of the cutting tool. The machining process is carried out under dry cutting conditions with variations of high velocity Vc, feeding rate f, and a cutting depth a at minimum rate conditions. The wear growth curve obtained shows that the CBN tool undergoes three phases: the initial phase, the gradual phase, and the abrupt phase. From the results of the study found that the failure modes that occur are flank wear, crater wear, flaking, chipping, and fracturing catastrophic failure. The wear mechanism that occurs in outline is caused by abrasive, adhesive, and diffusion processes. While the cracks and fractures that occur due to a combination of impact load and thermal shock

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Sami Ullah Khan and Wasim Jamshed. "Finite Element Analysis and Wear Rate Analysis of Nano Coated High Speed Steel Tools for Industrial Application." Babylonian Journal of Mechanical Engineering 2023 (February 20, 2023): 13–19. http://dx.doi.org/10.58496/bjme/2023/002.

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Numerous machining process output metrics may be used to evaluate a material's machinability, with tool life unquestionably being the most popular. The rate of tool wear, which is heavily reliant on the current wear mechanisms, determines the tool life in the main. The problem of tool wear needs to be rectified to improve machining quality such as surface roughness and production time. In this study, the thermal barrier coating (TBC) technique on machining tool (HSS) to improve its effectiveness. Utilizing Zirconia and Chromium-based compounds, the HSS tool have been coated. FEA (ANSYS software) was used to examine the material strength and wear of the suggested HSS tool. The tool life for machining is improved by suggesting these nano coated tools. Through this project's efforts, a cutting-edge tool might also be recommended.

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S, Ganeshkumar, Deepika T, and Anandakumar Haldorai. "A Supervised Machine Learning Model for Tool Condition Monitoring in Smart Manufacturing." Defence Science Journal 72, no. 5 (2022): 712–20. http://dx.doi.org/10.14429/dsj.72.17533.

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In the current industry 4.0 scenario, good quality cutting tools result in a good surface finish, minimum vibrations, low power consumption, and reduction of machining time. Monitoring tool wear plays a crucial role in manufacturing quality components. In addition to tool monitoring, wear prediction assists the manufacturing systems in making tool-changing decisions. This paper introduces an industrial use case supervised machine learning model to predict the turning tool wear. Cutting forces, the surface roughness of a specimen, and flank wear of tool insert are measured for corresponding spindle speed, feed rate, and depth of cut. Those turning test datasets are applied in machine learning for tool wear predictions. The test was conducted using SNMG TiN Coated Silicon Carbide tool insert in turning of EN8 steel specimen. The dataset of cutting forces, surface finish, and flank wear is extracted from 200 turning tests with varied spindle speed, feed rate, and depth of cut. Random forest regression, Support vector regression, K Nearest Neighbour regression machine learning algorithms are used to predict the tool wear. R squared, the technique shows the random forest machine learning model predicts the tool wear of 91.82% of accuracy validated with the experimental trials. The experimental results exhibit flank wear is mainly influenced by the feed rate followed by the spindle speed and depth of cut. The reduction of flank wear with a lower feed rate can be achieved with a good surface finish of the workpiece. The proposed model may be helpful in tool wear prediction and making tool-changing decisions, which leads to achieving good quality machined components. Moreover, the machine learning model is adaptable for industry 4.0 and cloud environments for intelligent manufacturing systems.

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Journal articles on the topic 'Tool wear rate'

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