Effects of calcium-treatment of a plastic injection mold steel on the tool wear and power consumption in slot milling

Milan, Júlio César Giubilei; Machado, Álisson Rocha; Tomaz, Ítalo; Silva, Leonardo R.R. da; Barbosa, Celso Antonio; Mia, Mozammel; Pimenov, Danil Yurievich

doi:10.1016/j.jmrt.2021.05.021

Cited by 12 publications

(5 citation statements)

References 33 publications

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“…Pachorkar et al [24] performed similar work, minimising sink marks and cycle time of injection-moulded polypropylene par using a Taguchi-based utility concept. Milan et al [25] compared the machinability of untreated AISI P20 with calcium-treated AISI P20 with different cutting inserts and reported that calcium-treated tools had increased life during slot milling. Zabala et al [26] investigated the performance of surface-treated two-mould materials and reported that Ni-PTFE-coated plastic material provided better mechanical and surface characteristics.…”

Section: Introductionmentioning

confidence: 99%

Weight Optimization of Plastic Injection Moulded Electrical Wire Casing Thermoplastic using Hybrid RSM-Tunicate Swarm Algorithm

Barua,

Jeet,

Mishra

et al. 2023

E3S Web Conf.

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The need for fire-retardant material for electrical wire covers and cases is increasing as the global population continues to expand at an alarming rate. In addition to having good fire and chemical resistance, CPVC (chlorinated polyvinyl chloride) is widely accessible in a assortment of forms and sizes, comprising rods, sheets, and tubes. Plastic injection moulding (PIM) provides a method that allows for the production of CPVC items at a rapid pace and at a low cost. When these mouldings are lightweight, they may reduce the amount of non-biodegradable materials that are used in their construction. The present research gives an insight into the CPVC material moulding for electrical wire casing elbows using an injection moulding machine, which was previously unexplored. Four plastic injection moulding parameters were considered in order to reduce the weight of the elbow, including injection pressure, mould closing speed, mould pressure, and backpressure. The 27 tests were piloted in line with Response Surface Methodbased Box-Behnken Design, and the factors were optimised using Tunicate Swarm Algorithm, which was recently developed. In the case of the plastic injection-moulded item, the analysis of variance revealed that the most significant parameter in the weight reduction was the material used. It has been determined that mould pressure is the most critical factor impacting the weight of the item when it is manufactured. As a result, the optimum manufacture of injection-moulded CPVC components will be facilitated, resulting in optimised weight while also minimising production time and raw material waste for electrical wire casing.

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Section: Introductionmentioning

confidence: 99%

Weight Optimization of Plastic Injection Moulded Electrical Wire Casing Thermoplastic using Hybrid RSM-Tunicate Swarm Algorithm

Barua,

Jeet,

Mishra

et al. 2023

E3S Web Conf.

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show abstract

“…Moreover, Farid et al [2] reported Taylor's tool life equation on the basis of the criterion of 100-µm flank wear at an outer corner while highspeed drilling of A383 Al-Si alloy using uncoated, TiAlN-and AlTiN-coated tools with various cutting parameters based on a central composite design of experiments. In milling operations, Milan et al [3] proposed an extended Taylor's tool life equation based on the tool life criterion of average flank wear of 0.4 mm when milling the calcium-treated and nontreated mold steels (AISI P20 and P 20 UF steels) using the three coatings TiN-, Al 2 O 3 -, and TiCN-coated carbide cutting tools. Kuo et al [4] formulated Taylor's tool life equation as a function of cutting time based on the maximum flank wear criterion of 0.3 mm during milling of superalloy Inconel 718 using uncoated, TiN-, and TiCN-coated tools.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the influence of cutting speed and feed rate on tool life in hard turning of AISI 4140 steel

Paengchit,

Saikaew

2023

Materials Science-Poland

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Tool life performances of Al2O3+TiC and TiN+AlCrN tool inserts were investigated experimentally under different cutting conditions in turning AISI 4140 steel. The tool life model is defined in accordance with a maximum surface roughness of 0.8 μm for the tool life criterion. The relationships between machining factors (i.e., cutting speed and feed rate) and tool life were obtained by Taylor’s formular. The sensitivity of cutting speed and feed rate to tool life was evaluated by Monte Carlo simulation. The results showed that turning with high cutting speeds and feed rates decreased the tool life of both inserts. At different cutting speeds and feed rates, Al2O3+TiC exhibited better tool life performance than TiN+AlCrN. In addition, the simulation results indicated the average tool life of Al2O3+TiC was approximately 40% greater than that of TiN+AlCrN by varying cutting speeds below and above the cutting speed of 220 m/min while keeping the feed rate constant at 0.06 mm/rev. Similarly, when keeping the cutting speed constant at 220 m/min, the average tool life of Al2O3+TiC was approximately 45% greater than that of TiN+AlCrN by varying feed rates below and above the feed rate of 0.06 mm/rev. Variations of tool life values by varying cutting speeds were more sensitive than those by varying feed rates for both tool inserts.

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“…21 Apart from this, two primary tool wear mechanisms that is, adhesion and abrasion were noticed during machining of non-treated steel while adhesion wear mechanism for the calcium treated steel along with chipping of the cutting edge at longer tool live. 22 Despite the fact, Bustillo et al 23 studied the outcome of a new machining strategy for accuracy improvement of the machine-learning model. In a major study, the researchers have investigated the performance of cryogenic treated CBN inserts, 24 carbide inserts, 25 and ceramic inserts 26 within the dry turning environment of C22 superalloy.…”

Section: Introductionmentioning

confidence: 99%

Analysis and prediction of tool wear in dry turning of hardened D3 steel using hybrid insert: A novel wear map approach

Rath

Panda

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Previously cubic boron nitride (CBN) and ceramic inserts were used for the dry turning of heat-treated D3 tool steel with cutting speed beyond 200 m/min, suffers from severe tool wear and generation of high temperature at the interface. To overcome these shortcomings, a hybrid ceramic insert that is, Al2O3 + Ti (C,N) with coated (TiN) is used in dry turning of D3 tool steel (heat-treated). Use of the hybrid insert with a lower feed rate (0.04 mm/rev) and a minimum depth of cut (0.4 mm) improves the surface quality of the turning process by significantly reducing the tool wear and cutting forces requirement in a cutting speed range of 165– 175 m/min. Even though ceramic tool inserts have high wear resistance at elevated temperatures but it has limited impact strength. So, ceramics is only recommended for shocks and vibration-free high-speed cutting operations of hardened steel under a dry environment. The novelty of this article is the development of a wear map for the analysis and prediction of tool wear. The Scanning electron microscope studies of wear region elucidate that low tool wear that the predominant modes of wear for low tool wear cutting conditions are delamination and abrasion. Besides for higher tool wear the prevailing wear mode is a combination of abrasion as well as adhesion wear. It is perceived that our proposed methodology outperforms the state-of-the-art methods.

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Effects of calcium-treatment of a plastic injection mold steel on the tool wear and power consumption in slot milling

Cited by 12 publications

References 33 publications

Weight Optimization of Plastic Injection Moulded Electrical Wire Casing Thermoplastic using Hybrid RSM-Tunicate Swarm Algorithm

Weight Optimization of Plastic Injection Moulded Electrical Wire Casing Thermoplastic using Hybrid RSM-Tunicate Swarm Algorithm

Simulation of the influence of cutting speed and feed rate on tool life in hard turning of AISI 4140 steel

Analysis and prediction of tool wear in dry turning of hardened D3 steel using hybrid insert: A novel wear map approach

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