Cutting force modeling considering tool wear effect during turning of hardened AISI 4340 alloy steel using multi-layer TiCN/Al2O3/TiN-coated carbide tools

Chinchanikar, Satish; Choudhury, S.K.

doi:10.1007/s00170-015-7662-5

Cited by 34 publications

(9 citation statements)

References 33 publications

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“…Austenitic stainless steel is one of the most important engineering materials with wide variety of applications. The problems such as poor surface finish and high tool wear are common while machining these materials [5][6][7]. A large number of articles are available in journals and books on machining performance of stainless steel and from these investigations many supportive results have been obtained.…”

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confidence: 82%

Machinability Investigations of Stainless Steel (304 L) using different Inserts

Singh¹

2018

IJRASET

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Austenitic stainless steel (304L) is one of the most important engineering materials with wide variety of applications because of its properties such as high hardness, toughness, yield strength, excellent ductility, and superior resistance to corrosion and oxidation. However, their machinability is more difficult as compared to other alloy steels due to low thermal conductivity, high built-up edge (BUE) formation tendency and high deformation hardening. Hence, the aim of this paper is to study the performance of different coated carbide inserts and to find out the optimum parameters while dry machining of SS304 L. The design of experiment was done using design expert, where cutting speed, feed rate, depth of cut and nose radius were taken as input parameters. The output responses were the surface roughness and tool wear. Total nine experiments were performed on CNC lathe machine using coated carbide, uncoated carbide and ceramite inserts. The overall results revealed that the optimum flank wear are found 0.12 mm against a combination of input parameters i.e. cutting speed 75m/min, feed rate 0.05mm/rev, depth of cut 0.25 mm using coated carbide inserts. Similarly, the optimum surface roughness were found 0.4 mm against a combination of input parameters i.e. cutting speed 125m/min, feed rate 0.05mm/rev, depth of cut 0.75mm using a tool uncoated carbide inserts. Keywords: Dry turning, CNC, Inserts, steel, cutting speed I.INTRODUCTION Steels represent the most important engineering materials as they have the widest diversity of applications of any of the engineering materials. Basic classes of steel are: plain carbon steels and alloy steels. In plain carbon steels the amount of alloying elements are negligible as compared to carbon, hence do not have the effect on the properties of the steels. Further according to the percentage of carbon (1.0%wt.Max) the plain carbon steels are classified as: low carbon steel, medium carbon steel and high carbon steel. Whereas allow steels are those steels in when one or more allowing elements are added in sufficient amount intestinally to the plain carbon steels to induce the required properties. Stainless steel is the sub class of allow steels containing various allowing elements: chromium, silicon, nickel, manganese and molybdenum. Stainless steels are stainless as these have minimum of 11.5%chromium in them,which having more affinity for oxygen than iron. Chromium forms a very thin, protective and stable oxide (Cr 2 O 3 ) film on the surface [1][2]. This film is continuous, impervious and passive to stop further reaction between the steel and the surrounding atmosphere. Thus chromium imparts to the steels corrosion resistance, oxidation resistance and pleasing appearance. Apart from the essential element chromium, the stainless steels also contain nickel, molybdenum and manganese to enhance other properties and improve the corrosion resistance. Stainless steels have become versatile because of its properties; good corrosion and oxidation resistance, good creep strengt...

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confidence: 82%

Machinability Investigations of Stainless Steel (304 L) using different Inserts

Singh¹

2018

IJRASET

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“…Chinchanikar and Choudhury [41] established a cutting force model under oblique cutting conditions considering tool wear, tool life, geometric tolerance of the finished product, and surface finish. Their approach was validated with the experimental results from turning hardened AISI 4340.…”

Section: Slip-line Field Modelsmentioning

confidence: 99%

Drilling Burr Formation With Tool Wear

Mandra¹

2021

Preprint

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Automated assembly processes are being widely used in aircraft manufacturing as a hole must be drilled before fastener installation. Burr formation is of importance for machining processes including drilling. A burr, an unwanted by‐product of machining, is a raised edge that remains attached to a workpiece because of the loss of shear action. In drilling, burrs form as the drill enters and exits the part, particularly when the tool becomes worn. Burrs require an additional process to deburr, incurring extra cost and time. To understand drilling burr formation, this dissertation presents a new model that combines a burr model with a tool‐wear model. The first adopted model describes a burr with respect to its height and thickness and relates burr formation to the drilling thrust force generated from drilling with a sharp tool. This model comprises a number of key factors: part material property, tool geometry, and drilling parameters. In reality, these factors will vary. Preliminary work was done to use this model to develop a sensitivity matrix for the purpose of studying the effect of variation in the key factors on burr formation. Unfortunately, tool wear, which is a major issue, cannot be simply considered as a variation in tool geometry. When a tool becomes worn, the cutting edge radius becomes large, and the cutting action changes from shearing to ploughing. A second model adopted is a tool wear model, leading to the core work of this dissertation. The aim of this study is to develop a drilling burr‐formation model for realistic conditions, incorporating variance within the tool and process parameters. The proposed method applies a weighting model that can consider the wear/no‐wear condition for each segment, thereby leading to a hybrid model for drilling burr formation. The research method is validated through simulation and an experiment entailing the generation of drilling burrs in conditions mimicking those in aerospace manufacturing. The results show that the model successfully estimates burr height and thickness trends with increasing levels of tool wear, for penetrated holes. The methods and results presented in this dissertation show good promise for understanding the effects of tool wear on drilling burr growth.

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“…Advanced coating techniques have been applied on cemented carbide cutting tools in order to prolong the tool life and improve the machining quality in industrial applications [1][2][3]. Under the current environment protection situation, the application of conventional metal cutting with cutting fluid exhibit great limitations.…”

Section: Introductionmentioning

confidence: 99%

Finite element investigation of cutting performance of Cr/W-DLC/DLC composite coated cutting tool

Hao

Zhang

et al. 2021

Int J Adv Manuf Technol

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Coupled with a thermo-mechanical metal cutting process, rapid tool wear, higher surface roughness and mass heat are caused by the rapid plastic deformation of the workpiece and by the friction along the tool-chip interface. This phenomenon is more predominant in the machining of difficult-to-cut materials. DLC film has been applied as coating material in the machining of difficult-to-cut materials, and shows a good cutting performance. In this study, Cr/W-DLC/DLC coated tools were compared with other three coated tools (i.e., TiC-, TiAlN-, Al 2 O 3 -) to investigate the cutting performance in the machining of Al-Si alloy (AC9B). In addition, the influence of Cr/W-DLC/DLC coated tools on the cutting performance under different cutting speeds was studied. Cutting force, cutting temperature, heat transfer coefficient of the rake face of the tool, cutting deformation rate, plastic deformation of machined surface, the interface temperature and stress were investigated numerically based on Finite Element Method (FEM). Actual cutting experiments were carried out to the verification of the FEM models by means of the cutting force and cutting temperature measurement. The investigation results showed that Cr/W-DLC/DLC coated tools has the lowest cutting force and cutting temperature, good cutting deformation characteristics and lower coating-substrate interface temperature and stress, however appears the maximum value of heat partition coefficient into the cutting tool. With the increasing of cutting speeds, cutting force and cutting temperature showed an increase trend, while the plastic deformation depth of machined surface and heat partition into cutting tool all showed a decrease trend. This investigation can provide the theory basis or technical guidance for the cutting practice of Cr/W-DLC/DLC coated tools.

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Cutting force modeling considering tool wear effect during turning of hardened AISI 4340 alloy steel using multi-layer TiCN/Al2O3/TiN-coated carbide tools

Cited by 34 publications

References 33 publications

Machinability Investigations of Stainless Steel (304 L) using different Inserts

Machinability Investigations of Stainless Steel (304 L) using different Inserts

Drilling Burr Formation With Tool Wear

Finite element investigation of cutting performance of Cr/W-DLC/DLC composite coated cutting tool

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