Evolution of cutting forces and tool failure mechanisms in intermittent turning of hardened steel with ceramic tool

Gong, Feng; Zhao, Jun; Pang, Jiming

doi:10.1007/s00170-016-9178-z

Cited by 19 publications

(15 citation statements)

References 24 publications

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“…29,34 Because of their brittleness, ceramic tools are usually subjected to chipping. 35,36 Performing a machining operation with a chipped edge affects the workpiece quality. The adhesive effect of the workpiece material and the high thermo-mechanical stresses on the cutting tool are considered to be the main reasons of chipping.…”

Section: Introductionmentioning

confidence: 99%

Tool wear and chip formation during dry high speed turning of direct aged Inconel 718 aerospace superalloy using different ceramic tools

Shalaby

Veldhuis

2019

Proceedings of the Institution of Mechanical Engineers, Part J:

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Direct aged Inconel 718 superalloy is used in manufacturing critical cross-sections of aero-engine components. It is a hard-to-machine material, especially in dry conditions. To perform successful machining operations for this alloy, cutting tools with high hot hardness and chemical stability are required. The present study investigates the tool wear and chip formation during dry finish turning of direct aged Inconel 718 superalloy (51–53 HRC) using different ceramic tools. Pure alumina with added ZrO2 and alumina matrix reinforced with silicon carbide whiskers tools were used at cutting speeds of 150 and 250 m/min. A scanning electron microscope and energy dispersing spectroscopy were utilized to study the tool wear mechanisms. Structural and phase transformations during cutting on the tool–chip interface at the higher cutting speed were analyzed with X-ray photoelectron spectroscopy. Chip-undersides and cross-sections were studied with scanning electron microscope to investigate the chip formation mechanism. Results reveal that pure alumina with added ZrO2 can be an adequate choice for machining direct aged Inconel 718 because of its higher abrasive wear resistance and the formation of a sapphire protective tribo-layer at the tool–chip interface under severe cutting conditions. Chipping and notching of the cutting edge was found to decrease with the rise of the cutting speed for this tool material. As confirmed by X-ray photoelectron spectroscopy, alumina reinforced with silicon carbide whiskers tool was found to have a lower performance due the chemical degradation of the whiskers, especially at the higher cutting speed (250 m/min).

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Section: Introductionmentioning

confidence: 99%

Tool wear and chip formation during dry high speed turning of direct aged Inconel 718 aerospace superalloy using different ceramic tools

Shalaby

Veldhuis

2019

Proceedings of the Institution of Mechanical Engineers, Part J:

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“…The CNC milling machine of DAEWOO ACE-V500 with the range of spindle speed from 80 to 10,000 rpm was used in the present experiment. The previous researches showed that the cutting depths had a great effect on tool cutting performance when cutting hardened steel [23,24]. Therefore, the single-factor experiments with cutting depths variables were conducted to explore the mechanisms of tool wear and breakage.…”

Section: Cutting Testsmentioning

confidence: 99%

Wear and breakage of coated carbide tool in milling of H13 steel and SKD11 hardened steel

Gong

Zhao

et al. 2019

SN Appl. Sci.

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In the present paper, the wear and breakage mechanisms of coated carbide tools are investigated in milling of H13 steel (HRC 30-35) and SKD11 hardened steel (HRC 58-62). The experiment results indicate that the hardness of workpiece has a dominant effect on tool failure patterns. Due to the low hardness of H13 steel, low-stress-repeated impact load on the tool induces the generation of cracks, but not enough to cause tool fracture. Thus, tool failure pattern is flank wear in milling of H13 steel. In contrast, the high-stress-repeated impact load facilitates the initiation and propagation of cracks and ultimately leads to breakage of rake face when milling SKD11 hardened steel. The geometry model of tool wear and breakage is established to explore the variation of tool angle. It is found that the flank wear reduces the clearance angle, while the breakage of rake face decreases the rake angle. In addition, the effect of tool wear and breakage on the cutting forces and chip formation is studied. The flank wear increases the friction coefficient between tool and H13 steel, and the breakage of rake face increases chip deformation and reduces the sharpness of cutting edge, both of which result in the increase in cutting forces. Furthermore, the wave-shaped chips are formed throughout milling of H13 steel, while the breakage of rake face results in the curling and separation of sawtooth chips when milling SKD11 hardened steel.

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“…4 And the fracture area of ceramic tool was mainly determined by mechanical stress, while damage depth was related to thermal stress in intermittent turning process. 5 The graded and homogeneous ceramic tools showed ladder-like fracture under thermal and mechanical shock in the intermittent turning alloy. 6 Specially, Cui and Guo 7 researched the effects of microscopic geometry of ceramic tool surface on tool temperatures in interrupted turning.…”

Section: Introductionmentioning

confidence: 98%

“…3,4 Many studies mainly concentrated on the effects of tool material and processing parameters on tool failure in cutting hardened steels. [4][5][6][7] The tool failure mechanisms differed with the variations in cutting conditions. Furthermore, the final failures of ceramic tools had the characteristics of a typical fatigue crack extension in intermittent cutting.…”

Section: Introductionmentioning

confidence: 99%

Fatigue failure analysis of ceramic tools in intermittent cutting harden steel based on experiments and finite element method

Zhao

Gong

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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The major concern of this article is the fatigue failure mechanisms of ceramic cutting tools with the help of intermittent turning experiment and simulation. Finite element simulation was adopted to analyze the spatial and temporal distribution of the stress on the cutting tools. The crack initiation and expansion life in the different positions was researched based on the fatigue crack model. The experiment results showed that the fracture area of flank face reduced with the increase in feed rates, while the fracture area and damage depth of rake face both increased. Through the simulation of fatigue crack, it could be inferred that fatigue fractures were caused by coalescence of cracks. When the feed rate was greater than or equal to 0.2 mm, tool failure was mainly manifested as fatigue fracture of the rake face. And the results of fatigue crack propagation simulation well predicted the cutting tool life. A novel research method for tool fatigue failure was provided.

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Evolution of cutting forces and tool failure mechanisms in intermittent turning of hardened steel with ceramic tool

Cited by 19 publications

References 24 publications

Tool wear and chip formation during dry high speed turning of direct aged Inconel 718 aerospace superalloy using different ceramic tools

Tool wear and chip formation during dry high speed turning of direct aged Inconel 718 aerospace superalloy using different ceramic tools

Wear and breakage of coated carbide tool in milling of H13 steel and SKD11 hardened steel

Fatigue failure analysis of ceramic tools in intermittent cutting harden steel based on experiments and finite element method

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