Cutting edge wear in high-speed stainless steel end milling

Malekan, Mohammad; Bloch-Jensen, Camilla D.; Zolbin, Maryam Alizadeh; Ørskov, Klaus Bonde; Jensen, Henrik Myhre; Aghababaei, Ramin

doi:10.1007/s00170-021-07006-5

Cited by 9 publications

(2 citation statements)

References 29 publications

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“…New materials and coatings for tool purposes with improved physical, mechanical, and operational properties are of particular interest for modern machine-building enterprises. A cutting tool with higher efficiency can significantly improve the quality of machined parts and minimize energy and resource consumption for cutting when using expensive multi-axis computer numerical control (CNC) machine tools for high speed machining [20][21][22][23][24]. The operation of such machines is characterized by a high machine hour cost, increased cutting tool heat and power loads due to the need to intensify cut-ting conditions, and an increase in tool consumption per output unit.…”

Section: Cutting Tool Performance and Amc Challengesmentioning

confidence: 99%

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

et al. 2021

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The paper proposes a classification of adaptive materials and coatings for tool purposes, showing the ability to adapt to external heat and power influences, thereby improving tool life. Creating a cutting tool made of composite powder high speed steels containing refractory TiC, TiCN, and Al2O3 compounds for milling 41CrS4 steel demonstrated the effectiveness of the adaptive materials. The tool material characteristics under the external loads’ influence and the surface layer adaptation to the heat–power exposure conditions were shown by the temperature field study using a semiartificial microthermocouple method (the level of fields is reduced by 20%–25% for 80% HSS + 20% TiCN), frictional interaction high-temperature tribometry (the coefficient of friction did not exceed 0.45 for 80% HSS + 20% TiCN at +20 and 600 °C), laboratory performance tests, and spectrometry of the surface layer secondary structures. Spectral analysis shows the highest spectrum intensity of TiC2 after 5 min of running in. After 20 min of milling (V = 82 m/min, f = 0.15 mm/tooth), dicarbide decomposes and transits to thermally stable secondary phase films of good lubricity such as TiO (maximum) and TiN (partially). There was an increase in tool life of up to 2 times (>35 min for 80% HSS + 20% TiCN), and a decrease in the roughness of up to 2.9 times (Ra less than 4.5 µm after 25 min of milling).

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Section: Cutting Tool Performance and Amc Challengesmentioning

confidence: 99%

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

et al. 2021

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“…[12][13][14] The use of steady-state analysis methods and empirical methods based on milling cutter wear experiments cannot correctly describe and identify the non-steady-state frictional wear processes of high-efficiency milling cutters, resulting in the actual service life of milling cutters being much less than the predicted minimum service life. 15,16 To solve this problem, it is necessary to construct a solution model that can correctly characterize the instantaneous contact relationship and instantaneous friction variables under the combined influence of multiple factors, so as to realize the effective correlation between the initial process variables of milling, the cutting process variables and the unsteady friction and wear characteristics of multiple teeth of the milling cutter.…”

Section: Introductionmentioning

confidence: 99%

Identification method for unsteady friction of tool flank for high efficiency milling cutter

Jiang,

Wang,

Zhao

et al. 2023

Advances in Mechanical Engineering

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Under the cutting loads of high efficiency and intermittent, the friction status between the tool flank and transition surface has time-varying characteristics, which directly affects friction and wear performance of the milling cutter. The dynamic distribution of instantaneous friction on tool flank under milling vibration needs to be revealed. In this work, the effect of milling vibration on instantaneous cutting contact relationship between milling cutter and workpiece was researched, a calculation method for the instantaneous friction velocity and friction energy consumption on tool flank was proposed. The variation of instantaneous friction between tool flank and transition surface under milling vibration was identified and evaluated by power spectral entropy and cross-correlation function. A method for identifying the unsteady friction of tool flank was proposed. The response analysis and experimental verification were conducted. The results showed that the frequency domain parameter distribution of friction energy consumption on tool flank had a strong correlation with the wear depth distribution, and was obviously sensitive to the milling parameters. The above models and methods could be used to reveal the influence of key milling process variables on unsteady friction and wear process of milling cutter’s multiple tool flank.

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Orthogonal cutting of 3D printed multi-material workpiece: numerical investigation of machining forces, stress, and temperature distribution

Ghasemi,

Duggen,

Malekan

2024

Int J Adv Manuf Technol

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With the development of 3D metal printers for rapid prototyping and industrial component production, heightened attention was directed towards post-processing operations for achieving precise surface quality and geometrical tolerances for these components. This paper investigated the orthogonal cutting of multi-material 3D printed workpieces using a coated cutting tool through finite element simulation. The workpieces featured different horizontal and vertical arrangements of layers composed of aluminum 7075-T6 alloy (Al), stainless steel 316 low alloy (SS), and Ti6Al4V alloy (Ti). The study explored the impacts of multi-material composition, coating thickness, and the rake angle of the cutting tool on machining forces, stress distribution, temperature distribution, and chip formation geometry. The results revealed a bimodal chip morphology in the machining process of horizontally arranged SS layers combined with other alloys. The SS layer resulted in a relatively uniform chip formation, while layers with two other materials exhibited a serrated chip formation. In contrast, a discontinuous chip formed when combining Al and Ti materials, as well as in the horizontally arranged layers made of Al, SS, and Ti alloys. The cutting force increased by 2.26 times when cutting workpieces with the horizontal arrangement of SS and Al layers compared to those with a single Al material. For the horizontal and vertical arrangement of layers made of Al and SS, von Mises stress values over the edge of the coated cutting tool significantly increased where the tool contacted the SS layer. Additionally, the horizontal arrangement of layers made of Al and SS materials caused the coated cutting tool to exhibit an extensive temperature distribution, with the maximum recorded temperature reaching 1448 °K. Increasing coating thickness led to a decrease in maximum principal stress at the surface of the tool and a rise in temperature at the cutting edge of the insert.

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Cutting edge wear in high-speed stainless steel end milling

Cited by 9 publications

References 29 publications

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

Application of Adaptive Materials and Coatings to Increase Cutting Tool Performance: Efficiency in the Case of Composite Powder High Speed Steel

Identification method for unsteady friction of tool flank for high efficiency milling cutter

Orthogonal cutting of 3D printed multi-material workpiece: numerical investigation of machining forces, stress, and temperature distribution

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