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Relevant bibliographies by topics / Wear in machining tools

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Academic literature on the topic 'Wear in machining tools'

Author: Grafiati

Published: 4 June 2021

Last updated: 15 February 2022

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Journal articles on the topic "Wear in machining tools"

1

Sousa, Vitor F. C., João Castanheira, Francisco J. G. Silva, José S. Fecheira, Gustavo Pinto, and Andresa Baptista. "Wear Behavior of Uncoated and Coated Tools in Milling Operations of AMPCO (Cu-Be) Alloy." Applied Sciences 11, no. 16 (2021): 7762. http://dx.doi.org/10.3390/app11167762.

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Copper-Beryllium alloys have excellent wear resistance and high mechanical properties, they also possess good electrical and thermal conductivity, making these alloys very popular in a wide variety of industries, such as aerospace, in the fabrication of tools for hazardous environments and to produce injection molds and mold inserts. However, there are some problems in the processing of these alloys, particularly when these are subject to machining processes, causing tools to deteriorate quite rapidly, due to material adhesion to the tool’s surface, caused by the material’s ductile nature. An assessment of tool-wear after machining Cu-Be alloy AMPCOLOY 83 using coated and uncoated tools was performed, offering a comparison of the machining performance and wear behavior of solid-carbide uncoated and DLC/CrN multilayered coated end-mills with the same geometry. Multiple machining tests were conducted, varying the values for feed and cutting length. In the initial tests, cutting force values were registered. The material’s surface roughness was also evaluated and the cutting tools’ edges were subsequently analyzed, identifying the main wear mechanisms and how these developed during machining. The coated tools exhibited a better performance for shorter cutting lengths, producing a lower degree of roughness on the surface on the machined material. The wear registered for these tools was less intense than that of uncoated tools, which suffered more adhesive and abrasive damage. However, it was observed that, for greater cutting lengths, the uncoated tool performed better in terms of surface roughness and sustained wear.

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Gao, Haining, Xianli Liu, and Zhitao Chen. "Cutting Performance and Wear/Damage Characteristics of PCBN Tool in Hard Milling." Applied Sciences 9, no. 4 (2019): 772. http://dx.doi.org/10.3390/app9040772.

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In the intermittent machining of hardened steel for the die and mold industry, determining how to reduce the wear of PCBN (Polycrystalline Cubic Boron Nitride) tools and improve their machining efficiency and quality is an important subject. This study investigated the intermittent machining of hardened steel (Cr12MoV, 59HRC (Rockwell hardness)) using uncoated PCBN tools to determine the cutting performance (cutting force, chip morphology, surface quality, tool life, cutting temperature) and the wear/damage characteristics of the tools. The results showed that the cutting performance of a PCBN tool was better than that of a cemented carbide tool. The wear mechanism on the PCBN tool flank was diffusion wear, adhesive wear, and oxidation wear. The main failure modes of the PCBN tool in the machining process of hardened steel at low speed were tool micro-chipping, the conchoidal damage of the rake face, and the larger damaged area of the flank face. The main failure modes of the PCBN tool in the machining process of hardened steel at high speed were flank wear and high-rate fatigue damage.

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Zhao, Guoyong, Yu Su, Guangming Zheng, Yugang Zhao, and Chunxiao Li. "Tool tip cutting specific energy prediction model and the influence of machining parameters and tool wear in milling." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234, no. 10 (2020): 1346–54. http://dx.doi.org/10.1177/0954405420911298.

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Most of the existing energy-consumption models of machine tools are related to specific machine components and hence cannot be applied to other machine tools with different specifications. In order to help operators optimize machining parameters for improving energy efficiency, the tool tip cutting specific energy prediction model based on machining parameters and tool wear in milling is developed, which is independent of the standby power of machine tools and the spindle no-load power. Then, the prediction accuracy of the proposed model is verified with dry milling AISI 1045 steel experiments. Finally, the influence of machining parameters and tool wear on tool tip cutting specific energy is studied. The developed model is independent of machine components, so it can reveal the influence of machining parameters and tool wear on tool tip cutting specific energy. The tool tip cutting specific energy reduces with the increase in the cutting depth, side cutting depth, feed rate, and cutting speed, while increases linearly as the tool wears gradually. The research results are helpful to formulate efficient and energy-saving processing schemes on various milling machines.

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Huang, Shu Tao, and Li Zhou. "Evaluation of Tool Wear when Milling SiCp/Al Composites." Key Engineering Materials 455 (December 2010): 226–31. http://dx.doi.org/10.4028/www.scientific.net/kem.455.226.

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The research on wear mechanism and characteristics of tool is a key issue for machining silicon carbide particle reinforced aluminum matrix composites (SiCp/Al). The machining adaptability, wear characteristics of the cermet cutting tools, TiN-coated tools and cemented carbide tools have been studied while milling SiCp/Al composites with large particle and high volume fraction. The results indicate that the wear resistance of the three kinds of tools are almost the same during machining large particle, high volume fraction SiCp/Al composite, and the tool wear is mainly presented as flank wear, which is caused by the mechanical wear of SiC particles. The wear rate of tools increases with increasing the cutting speed, but the difference is not very obvious. However, no matter high-speed cutting or low-speed cutting, the tool will be seriously worn in short distance. The each tooth cutter feed rate and depth of cutting have little effect on the tool wear.

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Pramanik, Alokesh, M. N. Islam, Animesh Basak, and Guy Littlefair. "Machining and Tool Wear Mechanisms during Machining Titanium Alloys." Advanced Materials Research 651 (January 2013): 338–43. http://dx.doi.org/10.4028/www.scientific.net/amr.651.338.

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This paper investigates the machining mechanism of titanium alloys and analyses those understandings systematically to give a solid understanding with latest developments on machining of titanium alloys. The chip formation mechanism and wear of different cutting tools have been analyzed thoroughly based on the available literature. It is found that the deformation mechanism during machining of titanium alloys is complex and it takes place through several processes. Abrasion, attrition, diffusion–dissolution, thermal crack and plastic deformation are main tool wear mechanisms.

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Ding, Zhi, Jiang Han, and Hai Dong Yang. "Wear Mechanisms of Hard-Brittle Material Tools in High-Speed Machining of Powder Metallurgy Material." Key Engineering Materials 693 (May 2016): 1200–1206. http://dx.doi.org/10.4028/www.scientific.net/kem.693.1200.

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A series of experiments was conducted in high speed machining of powder metallurgy material with PCBN tools. The main tool wear mechanisms were discussed by observing tool wear morphology utilizing scanning electron microscopy (SEM) and detecting the element distribution of the worn tool surface using energy dispersive spectroscopy (EDS).The experimental results indicate that fragile breakage occurred before it reached its blunt standard in high-speed machining of powder metallurgy material with PCBN tools,and the tools wear mechanisms are synergistic interaction among mechanical wear,binder wear and chemical wear.

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He, Lin Jiang, Jiu Hua Xu, Hong Hua Su, and Yan Chen. "Turning of Cast Inconel 718 with Coated Carbide and Whisker Reinforced Ceramic Tools." Materials Science Forum 770 (October 2013): 136–40. http://dx.doi.org/10.4028/www.scientific.net/msf.770.136.

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Nickel-based alloy is known as one of the most difficult-to-machine materials. During the machining process, the high temperature coupled with high strength and work hardening leads to excessive tool wear, short tool life, low productivity, etc. Tool life and material removal rate are the two targets of rough machining. In this paper, some turning tests are conducted to investigate the tool lives and material removal rate of coated carbide tools and whisker reinforced ceramic tools. The results show that notch wear is the dominant failure mode for whisker reinforced ceramic tools while severe flank wear and micro-chipping for coated carbide tools. The whisker reinforced ceramic tools are more effective in machining nickel-based alloys than the coated carbide tools both in tool life and material removal rate.

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Cichosz, Piotr. "Innovative machining tools and technologies." Mechanik 91, no. 10 (2018): 794–802. http://dx.doi.org/10.17814/mechanik.2018.10.133.

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Modern tools and innovative technologies used in machining are presented, and potential development directions of these manufacturing techniques are described. Particular attention is drawn to anti-wear tool materials and coatings, as well as structural elements of tools and machining strategies which strongly affect the broadly understood manufacturing efficiency.

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Zhu, Hong Yu, Wei Jin Chen, and Ying Li. "Wavelet Neural Network – Based Research on Online Wearing Prediction of TI6AL4V Cutter in High Speed Milling." Key Engineering Materials 431-432 (March 2010): 205–8. http://dx.doi.org/10.4028/www.scientific.net/kem.431-432.205.

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TI6AL4V is a kind of hard-machining material, which has bad thermal conductivity, good chemical reactivity, little elastic modulus, great friction coefficient, severe work hardening, short cutter life, low machining efficiency and poor machining surface quality. To improve the machining efficiency, reduce machining cost and improve products quality, the cutting tool wear is the key factor affecting machining quality, machining efficiency and production safety. In this paper, a test system which takes TI6AL4V as the research object, and the dynamic milling force during the high speed milling as the detection signal is built for online tools wear prediction. The method of wavelet packet transform and neural network are presented to diagnose and predict the situation of tools wear. The practical example shows that this system has good practicability and could identify the tools wear states exactly through verification tests.

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Kareem, B., and M. O. Idris. "Modeling Flank Wear Hardness of Selected HSS and HCS Single Point Cutting Tools with or without Cutting Fluid." Advanced Materials Research 367 (October 2011): 273–77. http://dx.doi.org/10.4028/www.scientific.net/amr.367.273.

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Conventional tool monitoring instruments are usually costly to acquire. The instruments are inadequate for real time wear measurement in the uncertain environmental conditions of developing countries. A modeling approach relating relevant parameters causing wear on cutting tools’ flank will be useful in predicting wear in machining operations. Mild steel turning experiment was carried out on the lathe using selected High Speed Steel (HSS) and High Carbon Steel (HCS) single point cutting tools. Speed, feed, and time of machining were varied accordingly, while running with, and without coolant. Hardness of the cutting tips of the tools was measured using Rockwell, R hardness tester. The corresponding speed, feed and time of machining were also noted. Turning operation was continued until the tool was totally blunt. At this stage recorded values of hardness, time of machining, feed and speed were modeled using multiple regression technique, with and without cutting fluid. The resulting models were strongly in agreement with the measured values. Therefore, the model is a good predictor of flank wear for the selected tools commonly used in developing countries. The findings showed that wear of the cutting tools can be predicted during machining at predetermined cutting conditions.

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Dissertations / Theses on the topic "Wear in machining tools"

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Fish, Randall K. "Dynamic models of machining vibrations, designed for classification of tool wear /." Thesis, Connect to this title online; UW restricted, 2001. http://hdl.handle.net/1773/6033.

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Odelros, Stina. "Tool wear in titanium machining." Thesis, Uppsala universitet, Institutionen för kemi - Ångström, 2012. http://urn.kb.se/resolve?urn=urn:nbn:se:uu:diva-176944.

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The present work was performed at AB Sandvik Coromant as a part in improving the knowledge and understanding about wear of uncoated WC/Co cutting tools during turning of titanium alloy Ti-6Al-4V. When machining titanium alloys, or any other material, wear of the cutting tools has a huge impact on the ability to shape the material as well as the manufacturing cost of the finished product. Due to the low thermal conductivity of titanium, high cutting temperatures will occur in narrow regions near the cutting edge during machining. This will result in high reaction and diffusion rates, resulting in high cutting tool wear rates. To be able to improve titanium machining, better knowledge and understanding about wear during these tough conditions are needed. Wear tests were performed during orthogonal turning of titanium alloy and the cutting tool inserts were analysed by SEM, EDS and optical imaging in Alicona InfiniteFocus. Simulations in AdvantEdge provided calculated values for cutting temperatures, cutting forces and contact stresses for the same conditions as used during wear tests. It was found that turning titanium alloy with WC/Co cutting tools at cutting speeds 30-60 m/min causes chamfering of the cutting tool edge and adhesion of a build-up layer (BUL) of workpiece material on top of the rake face wear land. The wear rate for these low cutting speeds was found to be almost unchanging during cutting times up to 3 minutes. During cutting speeds of 90-115 m/min, crater wear was found to be the dominating wear mechanism and the wear rate was found to have a linear dependence of cutting speed. An Arrhenius-type temperature dependent wear mechanism was found for high cutting speeds, between 90 and 115 m/min.

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Brown, Charles Jeremy. "An investigation of tool stresses caused by unsteady chip formations in machining." Thesis, Queen's University Belfast, 1986. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.236295.

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Taylor, Ciaran John. "The wear and performance characteristics of PCBN cutting tools when machining D3 hardened steel." Thesis, University of Hull, 2005. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.431046.

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Ghadimzadeh, Seyed Reza. "Machining of hypereutectic aluminium-silicon alloy." Thesis, Coventry University, 1995. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.281726.

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Chen, Wuyi. "The machining of hardened steel using superhard CBN tooling and CBN tipped rotary cutting tools." Thesis, University of Birmingham, 1993. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.342395.

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Rheinheimer, Carlos Eduardo Borsoi. "Influências do revestimento no desgaste da ferramenta no processo hobbing." reponame:Repositório Institucional da UCS, 2018. https://repositorio.ucs.br/handle/11338/3658.

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A alta demanda das indústrias, aliada a necessidade de alta eficiência, fomenta avanços tecnológicos na área de usinagem. Os revestimentos para recobrimento de ferramentas de usinagem vêm para atender essa necessidade, aumentando a durabilidade, e a confiabilidade das ferramentas. Este trabalho analisou o efeito de três diferentes revestimentos de ferramentas de usinagem (TiN, TiAlN e CrAlN) sobre o desgaste da ferramenta no processo de geração de engrenagens por hobbing. Para isso foram realizados ensaios experimentais utilizando uma única ferramenta hob, que após passar por processo de afiação recebeu os diferentes revestimentos. Os ensaios consistiram em medir o desgaste máximo de flanco (Vbmax) da ferramenta após a usinagem de um corpo de prova de um total de cinco, esses corpos de prova passaram por tratamento térmico de austenitização a fim de acelerar o desgaste. Além disso, a textura e a rugosidade dos corpos de prova foram analisadas em diferentes estágios da vida da ferramenta. Os resultados apontaram que o revestimento de TiAlN apresentou os menores valores de desgaste, estatisticamente igual ao CrAlN, e superiores ao TiN. O CrAlN apresentou os menores valores de rugosidade, e juntamente com o TiAlN foram os que apresentaram maior estabilidade para esta grandeza. Além disso, o TiAlN e o CrAlN em um comparativo econômico foram os apresentaram menor custo por corpo de prova usinado.<br>The high demand of the industries, together with the need for high efficiency, promotes technological advances in the area of machining. Machining tool coverings come to meet this need, increasing the durability, and reliability of the tools. This work analyzed the effect of three different machining tool coatings (TiN, TiAlN and CrAlN) on the wear of the tool in the process of generating gears by hobbing. For this, experimental tests were performed using a single hob tool, which after undergoing a sharpening process received the different coatings. The tests consisted in measuring the maximum flank wear (Vbmax) of the tool after machining a test piece of a total of five, these specimens underwent thermal treatment of austenitization in order to accelerate wear. In addition, the texture and roughness of the specimens were analyzed at different stages of tool life. The results indicated that the TiAlN coating had the lowest wear values, statistically equal to CrAlN, and higher than TiN. The CrAlN presented the lowest values of roughness, and together with the TiAlN were the ones that presented greater stability for this greatness. In addition, the TiAlN and CrAlN in an economic comparison were the lower cost per machined test specimen.

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Marafona, Jose Duarte R. "The influence of migrated materials on tool wear ratio." Thesis, Nottingham Trent University, 2002. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.268342.

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Li, Kuan-Ming. "Predictive Modeling of Near Dry Machining: Mechanical Performance and Environmental Impact." Diss., Available online, Georgia Institute of Technology, 2006, 2006. http://etd.gatech.edu/theses/available/etd-05122006-143200/.

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Thesis (Ph. D.)--Mechanical Engineering, Georgia Institute of Technology, 2007.<br>Dr. Liang, Steven Y., Committee Chair ; Dr. Melkote, Shreyes N., Committee Member ; Dr. Vengazhiyil, Roshan Joseph, Committee Member ; Dr. Zhou, Chen, Committee Member ; Dr. Zhou, Min, Committee Member.

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Hatt, Oliver. "On the mechanism of tool crater wear in titanium alloy machining." Thesis, University of Sheffield, 2016. http://etheses.whiterose.ac.uk/17231/.

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Today the aerospace industry spends hundreds of millions of dollars on the machining of titanium alloy components. And with increasing aircraft orders, there is pressure to machine at higher production rates and develop more machinable alloys (e.g. TIMETAL® 54M, TMETAL® 407) without compromising titanium’s excellent mechanical properties. Increasing the tool life by a factor of minutes can have a dramatic effect on machining cost. Unlike steels, the same tool grade is used for all titanium alloy types from alpha to beta rich, with the latter being more difficult to machine. Diffusion dominated crater wear is the primary tool wear phenomena which has yet to be fully understood. This thesis demonstrates the application of a low cost diffusion couple technique which gives a strong indication of the complex reaction mechanisms occurring at the tool-chip interface during the machining of titanium alloys. These small scale tests have been validated with large scale dynamic machining trials and strong agreement has been observed. The results have allowed for hypotheses to be made over the reaction mechanisms behind tool crater wear underpinned by key observations in the literature. Such a testing regime can be incorporated into alloy design approaches to inform the industry e.g. TIMET and Rolls-Royce about the ‘machinability’ qualities at a much earlier stage before costly machining trials. Such a method will also aid tool manufacturers to tailor tool carbide grades as well as new coatings to specific alloy chemistries. This is the first time that small scale testing such as this has shown why different alloy chemistries exhibit different tool wear characteristics. The technique is now being developed further by the aerospace manufacturing supply chain including tool manufacturers and titanium alloy producers. It will be used to; (a) develop more machinable alloys at an earlier stage in the alloy design development and (b) match different titanium alloys to more appropriate tool materials and new coatings. As such this thesis should be of interest to a broad readership including mechanical engineers and materials scientists as well as the machining and manufacturing community.

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Books on the topic "Wear in machining tools"

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CNC machining. The Goodheart-Willcox Company, 2008.

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Gizelbach, Richard. CNC machining. The Goodheart-Willcox Company, 2009.

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Youssef, Helmi A. Machining Technology. Taylor and Francis, 2008.

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Apro, Karlo. Secrets of 5-axis machining. Industrial Press, 2008.

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J, Campa F., and López de Lacalle, L. N., eds. Light machine tools for productive machining. Nova Science Publishers, 2011.

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Bajalan, M. R. Machining of steels with ceramic tools. typescript, 1992.

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1941-, Knight W. A., ed. Fundamentals of machining and machine tools. 3rd ed. Taylor and Francis, 2005.

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Youssef, Helmi A. Machining technology: Machine tools and operations. Taylor & Francis, 2008.

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Liang, Steven, and Albert J. Shih. Analysis of Machining and Machine Tools. Springer US, 2016. http://dx.doi.org/10.1007/978-1-4899-7645-1.

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López de Lacalle, L. N., and A. Lamikiz, eds. Machine Tools for High Performance Machining. Springer London, 2009. http://dx.doi.org/10.1007/978-1-84800-380-4.

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Book chapters on the topic "Wear in machining tools"

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Csanády, Etele, and Endre Magoss. "Tool Wear." In Mechanics of Wood Machining. Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-51481-5_7.

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Csanády, Etele, and Endre Magoss. "Tool Wear." In Mechanics of Wood Machining. Springer Berlin Heidelberg, 2012. http://dx.doi.org/10.1007/978-3-642-29955-1_7.

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Sheikh-Ahmad, Jamal Y. "Tool Materials and Tool Wear." In Machining of Polymer Composites. Springer US, 2009. http://dx.doi.org/10.1007/978-0-387-68619-6_4.

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Hosseini, Ali, and Hossam A. Kishawy. "Cutting Tool Materials and Tool Wear." In Materials Forming, Machining and Tribology. Springer Berlin Heidelberg, 2014. http://dx.doi.org/10.1007/978-3-662-43902-9_2.

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Sidpara, Ajay M., and Ganesh Malayath. "Tool Wear Modeling and Compensation Methods." In Micro Electro Discharge Machining. CRC Press, 2019. http://dx.doi.org/10.1201/9780429464782-10.

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Nadda, Rahul, Chandrakant Kumar Nirala, and Probir Saha. "Tool Wear Compensation in Micro-EDM." In Materials Forming, Machining and Tribology. Springer Singapore, 2018. http://dx.doi.org/10.1007/978-981-13-3074-2_9.

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El-Hofy, Hassan. "Tool Wear, Tool Life, and Economics of Metal Cutting." In Fundamentals of Machining Processes. CRC Press, 2018. http://dx.doi.org/10.1201/9780429443329-4.

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Baharudin, BT Hang Tuah, N. Dimou, and K. K. B. Hon. "Tool Wear Behaviour of Micro-Tools in High Speed CNC Machining." In Proceedings of the 34th International MATADOR Conference. Springer London, 2004. http://dx.doi.org/10.1007/978-1-4471-0647-0_17.

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Raebel, S., F. J. Worzala, and J. R. Conrad. "PSII Nitrogen Implanted M2 Tool Steel for Wear Resistance in Wood Machining Tools." In Surface Engineering. Springer Netherlands, 1990. http://dx.doi.org/10.1007/978-94-009-0773-7_21.

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Kumar, Sandeep, Akshay Dvivedi, and Pradeep Kumar. "On Tool Wear in Rotary Tool Micro-Ultrasonic Machining." In Proceedings of the 3rd Pan American Materials Congress. Springer International Publishing, 2017. http://dx.doi.org/10.1007/978-3-319-52132-9_8.

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Conference papers on the topic "Wear in machining tools"

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Li, Peng-Yang, Chong-Yang Hao, and Shuang-Wu Zhu. "Machining Tools Wear Condition Detection Based on Wavelet Packet." In 2007 International Conference on Machine Learning and Cybernetics. IEEE, 2007. http://dx.doi.org/10.1109/icmlc.2007.4370393.

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Waldorf, Daniel, Scott Liu, Michael Stender, and Daniel Norgan. "Alternative Binder Carbide Tools for Machining Superalloys." In ASME 2008 International Manufacturing Science and Engineering Conference collocated with the 3rd JSME/ASME International Conference on Materials and Processing. ASMEDC, 2008. http://dx.doi.org/10.1115/msec_icmp2008-72369.

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This study examines the performance of a new class of wear-resistant but economical cutting tools produced by varying the binder composition of standard cemented carbide composites. By replacing some or all of the cobalt binder with rhenium and nickel-based superalloy, a stronger composite tool results, potentially capable of machining heat-resistant superalloys at significantly higher cutting speeds. Sample tools with alternative binder were produced and compared to standard tools bound with cobalt only. Turning experiments on Inconel 718 were run to evaluate wear resistance and tool life for several grades. The experimentation also examined the effects of varying the relative proportions of each binder constituent as well as the overall binder percentage in the composite. Results show a clear advantage of the alternative binder tools as evidenced by a 150% increase in tool life or the equivalent of an 18% increase in cutting speed. Although increasing amounts of rhenium in the binder show a positive effect on performance, the effects of superalloy and overall binder % are inconclusive.

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Reddy Paturi, Uma Maheshwera, and Suresh Kumar Reddy Narala. "Finite Element Analysis and Study of Tool Wear in Machining With Coated Tools." In ASME 2013 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/imece2013-64342.

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Accurately predicting the tool wear in any machining process play an important role in enhancing the manufacturing process performance. In all machining operations, cutting tool wear is strongly influenced by contact temperatures, stresses, and relative sliding velocity at the machining interface. Based on cutting temperatures and stresses on the tool face predicted by the finite element simulations, tool wear can be estimated. This paper features a specific study of the application of solid lubricant coatings in machining operations and presents its influence on tool-workpiece contact temperature and tool wear resistance. In the present work, finite element modeling approach concerning orthogonal cutting was carried out in order to understand the machining process performance in terms of tool wear during turning of selected workmaterial with and without solid lubricant (molybdenum disulphide, MoS2) coated tools produced by electrostatic micro-solid lubricant coating technique. Finite element code, DEFORM-3D is utilized to predict the tool wear during machining of workmaterial under two machining environments. The results under similar tested machining conditions show that flank wear resistance was improved remarkably during machining with MoS2 coated tools when compared to machining with uncoated tools. This could be mainly due to the presence of MoS2 film on tool face, which can reduce the cutting temperatures effectively owing to its excellent lubricity action and result in lower specific cutting energy given into the contact. For experimental validation, series of turning tests were carried out under selected conditions. It has been observed from the simulation studies that the tool wear results are in reasonable agreement with the experimental results.

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Burger, Uli, Matthew Kuttolamadom, April Bryan, Laine Mears, and Thomas Kurfess. "Volumetric Flank Wear Characterization for Titanium Milling Insert Tools." In ASME 2009 International Manufacturing Science and Engineering Conference. ASMEDC, 2009. http://dx.doi.org/10.1115/msec2009-84256.

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Machining wear models are useful for the prediction of tool life and the estimation of machining productivity. Existing wear models relate the cutting parameters of feed, speed, and depth of cut to tool wear. The tool wear is often reported as changes in flank width or crater depth. However, these one-dimensional wear measurements do not fully characterize the tool condition when tools wear by other types of wear such as notching, chipping, and adhesion. This is especially true when machining difficult-to-machine materials such as titanium. This paper proposes another approach for characterizing tool wear. It is based on taking measurements of the retained volume of the cutting tool. The new wear characterization approach is used to demonstrate the progression of volumetric wear in titanium milling.

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Li, Kuan-Ming, and Steven Y. Liang. "Predictive Models for Flank Wear in Near Dry Machining." In ASME 2005 International Mechanical Engineering Congress and Exposition. ASMEDC, 2005. http://dx.doi.org/10.1115/imece2005-81502.

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The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

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6

Varghese, K. Philip, and A. K. Balaji. "On the Wear of Carbide and Cermet Tools in Machining of Compacted Graphite Iron (CGI)." In ASME/STLE 2007 International Joint Tribology Conference. ASMEDC, 2007. http://dx.doi.org/10.1115/ijtc2007-44367.

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This work presents an extension of a previous investigation [1] conducted on gaining an understanding of the critical tribological issues encountered in the machining of compacted graphite iron (CGI) using different cutting tool materials. As part of this study, wear tests were conducted on flat-faced coated and uncoated carbide tools and coated and uncoated cermet tools. The machining tests were conducted under dry condition. Performance assessment of the cutting tools was made using a comparative analysis of the measured cutting forces and post machining scanning electron microscopy (SEM) of used tools. The results reveal the interaction of selected cutting conditions and tool substrate material and coatings on the tribological performance and wear behavior of tools during CGI machining.

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Moura, Ricardo Ribeiro, and Álisson Rocha Machado. "Machining of VP20ISOF Steel With Resharpened Carbide Tools in End Milling." In ASME 2013 International Manufacturing Science and Engineering Conference collocated with the 41st North American Manufacturing Research Conference. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/msec2013-1052.

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The main objective of the present work is to determine the performance of resharpened integral coated cemented carbide end milling tools. Tools as new and after they have been resharpened were tested, during machining of hard steel used in the mold and die industry. The coatings used were TiAlN and AlCrN. The cutting speed was varied, keeping the depth of cut, the cutting width and the feed per tooth constants. Tests were carried out dry. A 23 factorial design was used, considering the following factors (and levels): cutting speed (80 and 100 m / min), tool coating (TiAlN and AlCrN) and the tool condition (new and reground). The output parameter considered is the tool life (wear rate). At the end of the tool life the wear mechanisms were analyzed within a Scanning Electron Microscopy - SEM. The results showed that in general the AlCrN coated tools outperformed the TiAlN. The performance of resharpened tools was very similar to the new tools, and statistically there is no significant difference between their tool lives.

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Sivakumar, R., M. Prasanna, K. Pradeep, V. T. Rajkumar, and S. Raj Kumar. "Wear characterization of ceramic tools (SiAlON and Al2O3+SiCWhisker) with dry and wet turning of Nimonic 75." In INTERNATIONAL CONFERENCE ON MATERIALS, MANUFACTURING AND MACHINING 2019. AIP Publishing, 2019. http://dx.doi.org/10.1063/1.5117934.

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Kuttolamadom, Mathew, Parikshit Mehta, Laine Mears, and Thomas Kurfess. "The Correlation of Volumetric Tool Wear and Wear Rate of Machining Tools With the Material Removal Rate of Titanium Alloys." In ASME 2012 International Manufacturing Science and Engineering Conference collocated with the 40th North American Manufacturing Research Conference and in participation with the International Conference on Tribology Materials and Processing. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/msec2012-7338.

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The objective of this paper is to assess the correlation of volumetric tool wear (VTW) and wear rate of carbide tools on the material removal rate (MRR) of titanium alloys. A previously developed methodology for assessing the worn tool material volume is utilized for quantifying the VTW of carbide tools when machining Ti-6Al-4V. To capture the tool substrate response, controlled milling experiments are conducted at suitable corner points of the feed-speed design space for constant stock material removal volumes. For each case, the tool material volumes worn away, as well as the corresponding volumetric wear profile evolution in terms of a set of geometric coefficients are quantified — these are then related to the MRR. Further, the volumetric wear rate and the M-ratio (volume of stock removed to VTW), which is a measure of the cutting tool efficiency, are related to the MRR — these provide a tool-centered optimal MRR in terms of profitability. This work not only elevates tool wear from a 1-D to 3-D concept, but helps in assessing machining economics from a stock material removal efficiency perspective as well.

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Agrawal, Shyam S., and Sanjay Agarwal. "Study of Tool Wear in EDM Using Statistical Design of Experiments." In ASME 2008 International Mechanical Engineering Congress and Exposition. ASMEDC, 2008. http://dx.doi.org/10.1115/imece2008-67166.

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The tool wear, while machining a part in electric discharge machining (EDM) process, is of great concern in the researchers in recent years as the accuracy of tool wear directly affects the accuracy of the parts to be produced. The variation in tool wear may occur due to variation in the machining parameters such as current, spark gap, pulse duration, voltage, flushing of dielectric fluid, mode of flushing of dielectrics, taper angle of the tool, etc. This paper represents the effect of current, taper angle of tool and pulse duration on the tool wear during electrical discharge machining of EN-31 tool steel, as this is one of the materials being used increasingly in cold forming rolls, knurling tools, press tools, lathe centers, etc. The experiments have been conducted using “Central Composite Rotatable Design”. Results indicate that the tool wear could be reduced if machining is performed at low current values and low pulse duration and it could be further reduced with increase in the taper angle of tool.

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Reports on the topic "Wear in machining tools"

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Fell, H. A. Investigation of machining damage and tool wear resulting from drilling powder metal aluminum alloy. Office of Scientific and Technical Information (OSTI), 1997. http://dx.doi.org/10.2172/541926.

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2

McSpadden, SB. Cylindrical Wire Electrical Discharge Machining of Metal Bond Diamond Wheels- Part II: Wheel Wear Mechanism. Office of Scientific and Technical Information (OSTI), 2002. http://dx.doi.org/10.2172/814385.

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