Failure analysis of ceramic tool in intermittent turning of hardened steel

Ni, Xiaowu; Zhao, Jun; Wang, Fuzeng; Gong, Feng; Zhong, Xin; Tao, Haiwang

doi:10.1177/0954405416684156

Cited by 7 publications

(6 citation statements)

References 34 publications

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“…The Vc factor comes in third place with a cont% of 10.75%, while r is nonsignificant P > 0.05 with a cont% of 0.41%. Gong et al [9] reported similar results, Cui et al [40], Ni et al [41] indicating that the increase of both factors ap and f causes the increase of effort Fz. From the ANOVA of Pm, it is obvious that all the input factors are significant; Vc and ap have the major influence, with a cont% of 40.37% and 39.93% respectively.…”

Section: Resultsmentioning

confidence: 56%

Statistical analysis, modeling and multi-objective optimization of parameters intermittent turning process of AISI D3

Khelfaoui

Yallese

Ouelaa

et al. 2023

JMES

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Intermittent machining is characterized by its complex and irregular context. This intermittency causes machining to occur under difficult conditions that greatly influence the technological performance parameters. The aim of the present work is to evaluate the effects of input parameters, cutting speed, Vc, depth of cut, ap, tool nose radius, r and feed rate, f, on surface roughness, Ra, tangential cutting force, Fz, motor power consumption, Pm, cutting power, Pc and material removal rate (MRR), during intermittent turning (IT) of AISI D3 tool steel. Machining was performed with a triple CVD coated carbide tool (AI2O3/TiC/TiCN) by adopting a Taguchi L9 (3^4) experimental design. The ANOVA and RSM methods were used to analyze the effects of cutting factors on the outputs parameters resulting in statistical prediction models. In addition, a multi-objective optimization of the cutting conditions exploiting the desirability function (DF) was done according to four cases of relative importance corresponding to different industrial contexts. Furthermore, the grey relational analysis (GRA) method was applied and compared with the DF method. The results show that the optimal regime found by the DF method, (r =1.6mm, Vc= 240 m/min, f = 0.084 mm/rev and ap = 0.64 mm), favors Ra and MRR. On the other hand, for the GRA method, the combination of (r = 0.4 mm, Vc = 240 m/min f = 0.08 mm/rev and ap = 0.3 mm) favors the minimization of Fz, Pm and Pc. This work presents an originality because the results found are very useful in the field of optimization for a better control of the process IT.

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Section: Resultsmentioning

confidence: 56%

Statistical analysis, modeling and multi-objective optimization of parameters intermittent turning process of AISI D3

Khelfaoui

Yallese

Ouelaa

et al. 2023

JMES

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“…However, the situation would be different when the cutting speed increased to 300 m/min, at which the cutting temperature was relatively high and the adhesive wear and diffusion wear would become serious. 26,29 Differing from the medium and low-speed machining, the effect of friction characteristics on tool life would be weak at high-speed machining free-cutting steels (300 m/min). Here, with combined action of serious adhesive wear and diffusion wear, intensified by the high cutting temperature, the tool lives would also be poor.…”

Section: Resultsmentioning

confidence: 99%

“…The increase of cutting speed would also enhance the cutting temperature. 10,29 The slight reduction of cutting force can be attributed to the thermal softening effect of free-cutting steel materials during machining. [30][31][32] Combined with the results of tool lives (Figure 3), it seems that the rapid decrease of tool lives at the speed of 300 m/min can also be attributed to the high temperature, which can intensify the main wear behaviors, such as adhesive wear and diffusion wear.…”

Section: Tool Life and Cutting Forcementioning

confidence: 99%

Study on the tool life analysis for free-cutting steels

Zhang

Yang

Tang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Experimental study and theoretical calculation on the tool lives of free-cutting steels with different additions were carried out in terms of the friction characteristics, chip deformation, and normal stress distribution. The average friction coefficient, shear angle, and maximum normal stress were then calculated, and the influence of them on tool life was analyzed and discussed carefully. The free-cutting steel with Bi addition (MB) presented the best tool life of about 9200 and 5200 s at the speed of 150 and 200 m/min, respectively, which was mainly due to the combined effect of the lower average friction coefficient, maximum normal stress, and higher shear angle. When the cutting speed increased to 300 m/min, the tool life decreased rapidly, which was mainly caused by the serious tool wear behavior dominated by the high cutting temperature. Differing from the calculated results of shear angles based on Lee and Shaffer’s assumption, the measured shear angles decreased with the cutting speed ranging from 150 to 250 m/min, resulting from the thermal softening of workpiece material during machining. Moreover, the present findings indicated that the cutting process became unstable when the maximum normal stress on the tool nose was larger than 2 GPa, where catastrophic failures occurred, resulting in accelerated fracture of the tool. The research findings not only give more insight into the effect of friction characteristics, chip deformation, and normal stress distribution on the tool lives, but also have significance for the machining of free-cutting steels.

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“…Furthermore, the average cutting forces increased with the increase in the feed rate in the intermittent cutting hardened steels. See the literature 34 for a detailed discussion. Spatial and temporal distribution of cutting stress.…”

Section: Tool Failure Mechanism Analysismentioning

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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Failure analysis of ceramic tool in intermittent turning of hardened steel

Cited by 7 publications

References 34 publications

Statistical analysis, modeling and multi-objective optimization of parameters intermittent turning process of AISI D3

Statistical analysis, modeling and multi-objective optimization of parameters intermittent turning process of AISI D3

Study on the tool life analysis for free-cutting steels

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

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