An Investigation of the Tool-Chip Interface Temperature and Heat Partition in High-speed Machining of AISI/SAE 4140 Steel with TiN-coated Tool

Akbar, Faraz; Mativenga, Paul; Sheikh, Mohammad

doi:10.1007/978-1-84628-988-0_48

Cited by 13 publications

(5 citation statements)

References 13 publications

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“…Cutting temperature (°C) -Cutting temperature has a significant impact on turning process since high cutting temperatures reduce tool life thereby increasing tooling cost and induces dimensional inaccuracies in the workpiece (Groover 2007). In this study, the rise in temperature at tool-chip interface has been calculated using an equation based on dimensional analysis developed by experimental data for a variety of work materials (Cook 1973) and has also been validated by a recent study for AISI 4140 alloy steel (Akbar et al 2007).…”

Section: Oil and Water Consumption (L/component) -This Refersmentioning

confidence: 97%

An integrated sustainability assessment framework: a case of turning process

Bhanot

Rao

Deshmukh

2016

Clean Techn Environ Policy

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Sustainable manufacturing is a valuable tool for measuring and enhancing the machining performance. The implementation of sustainability frameworks in concerned industries poses enormous challenges despite various frameworks available in the literature. Thus, the objective of this paper is to present an integrated sustainability assessment framework wherein two machining scenarios (dry and wet turning) have been analysed by conducting experiments based on the process for a manufactured component in an industry from economic and environmental perspectives. The study further evaluates the economic and environmental indicators such as cost per component and energy consumption for Taguchi array design using empirical relations to evaluate sustainability by grey relational analysis and further optimise the machining performance by particle swarm optimisation. The results, however, indicate the possibility of transitioning the machining process from wet to dry at specific operating conditions with improved performance. In addition to this, the study also presents an illustration of social sustainability assessment framework which has been proposed after consultation with various manufacturing industries in order to make it convenient for them to implement and enhance the sustainability aspects of the machining process.

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Section: Oil and Water Consumption (L/component) -This Refersmentioning

confidence: 97%

An integrated sustainability assessment framework: a case of turning process

Bhanot

Rao

Deshmukh

2016

Clean Techn Environ Policy

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“…The emissivities of an AISI 4140 alloy steel were measured as a function of the surface temperature. In the literature, the recommended emissivity value for AISI 4140 alloy steel is between 0.50 and 0.75 [ 28 ]. For an accurate measurement of the cutting temperature, different emissive values (in the range of 0.45–0.85) were tried in order to adjust the accuracy of the temperatures at constant cutting parameters.…”

Section: Experimental Conditionsmentioning

confidence: 99%

Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in Metal Cutting

Kuş

Işık

Çakır

et al. 2015

Sensors

126

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In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining.

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“…This methodology was successfully adopted previously by several researchers to evaluate average heat partition on the secondary deformation zone. 7,13,14,38–40…”

Section: Fe Transient Heat Transfer Analysismentioning

confidence: 99%

Critical design factors for multi-layer coating systems that influence heat partition in the secondary shear deformation zone and machining performance

Fahad

Mativenga

Sheikh

2012

Proceedings of the Institution of Mechanical Engineers, Part B:

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High thermal loads during the cutting process can have a major influence on tool performance. Multilayer coated tools can have a positive impact in improving machining performance, especially at high cutting velocities. In this study TiCN/Al2O3/TiN, TiCN/Al2O3 and TiCN/Al2O3–TiN multilayer chemical vapour deposition (CVD)-coated carbide cutting tool inserts, were investigated in dry turning of AISI/SAE 4140 over a wide range of cutting speeds of between 200 m/min and 879 m/min. While the TiCN/Al2O3/TiN and TiCN/Al2O3 coating layers were deposited uniformly around the insert, TiCN/Al2O3–TiN has TiCN/Al2O3 on the rake face and TiCN/Al2O3/TiN on the flank/clearance faces. For clarity, in this article it is addressed as (TiCN/Al2O3/TiN)flank (TiCN/Al2O3)rake and termed the functionally graded system. The investigations were based on experimental determination of cutting forces, chip compression ratio, tool–chip contact phenomena, and flank wear, as well as finite element modelling of heat partition into the cutting tool. Results show that two layered TiCN/Al2O3 deposited in series gives a better performance against the three layered TiCN/Al2O3/TiN and the functionally graded TiCN/Al2O3–TiN tools. Results from the cutting tests and finite element analysis suggest that selection of an appropriate top coating and optimised coating thickness are two important factors for achieving effective cutting performance.

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An Investigation of the Tool-Chip Interface Temperature and Heat Partition in High-speed Machining of AISI/SAE 4140 Steel with TiN-coated Tool

Cited by 13 publications

References 13 publications

An integrated sustainability assessment framework: a case of turning process

An integrated sustainability assessment framework: a case of turning process

Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in Metal Cutting

Critical design factors for multi-layer coating systems that influence heat partition in the secondary shear deformation zone and machining performance

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