Machining of Difficult-To-Cut Materials

Bleicher, Friedrich; Finkeldei, Daniel; Siller, Anton

doi:10.2507/27th.daaam.proceedings.071

Cited by 8 publications

(5 citation statements)

References 20 publications

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“…These multi-layer coatings have been found to outperform others when it comes to tool steel performance. Due to the advantages provided by layered coatings over single layers, TiAlN [10] is often combined with TiN in practical applications. The combination of layers in a tool enhances its durability and cutting efficiency.…”

Section: Coating Materials and Their Propertiesmentioning

confidence: 99%

Optimizing machining efficiency: a comprehensive study on PVD cathodic arc evaporation coated turning tool inserts with TiAlN/AlCrN multilayer coatings

et al. 2024

Mater. Res. Express

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The effectiveness of turning processes in manufacturing depends on the efficiency of cutting tool inserts. Coating these inserts is one common method that has been used to prolong their life span, reduce friction and increase wear resistance. The main purpose of the present study was to enhance the efficiency of turning tool inserts by exploring different combinations of coating substances such as TiAlN, AlCrN, and TiAlN/AlCrN. Cutting speed, feed rate, cutting depth and type of coating material were important input parameters for optimization. It was observed that tools with coatings like TiAIN and AlCrN had higher performance than those with single-layered ones. The use of multilayer coated inserts comprising TiAlN/AlCrN increased the hardness but reduced the wear thereby enhancing machining effectiveness. For Taguchi Grey Relation Analysis (GRA) optimization technique with L27 array for hardness and flank wear output parameters aimed at enhancement of input process parameters in turning operations. The coatings’ crystalline structure, phase composition and other crucial details for their performance were analyzed using Energy Dispersive (EDS) Spectroscopy and Scanning Electron (SEM) Microscopy techniques. The TiAlN/AlCrN coatings showed greater machinability than those with only TiAlN or AlCrN, even at high spindle speeds. The best processes were identified using the Taguchi and Grey relational optimization techniques. Some of these parameters include a speed of 600 m/min, a feed rate of 0.10 mm/rev, a depth of 1.5 mm, and a TiAlN/AlCrN coating. This meant that the hardness was at 3772 HV while flank wear is 6.45 mm for optimum parameters among others obtained from experiments. Various relationships can be displayed using contour plots which are usually visual representation between several factors in an experiment such as hardness and wear resistance which is shown by multilayer coating compared to single-layer coatings.

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Section: Coating Materials and Their Propertiesmentioning

confidence: 99%

Optimizing machining efficiency: a comprehensive study on PVD cathodic arc evaporation coated turning tool inserts with TiAlN/AlCrN multilayer coatings

et al. 2024

Mater. Res. Express

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“…In recent years, there has been active development of novel non-conventional finishing processes and improvement of conventional processes to achieve the high-quality surface finish of difficult-to-machine materials such as ceramics, titanium alloys, tungsten, cobalt, and inconel 718 [ 65 , 66 , 67 , 68 , 69 ]. Generally, the characteristics of difficult-to-machine materials include high hardness, high strength, high brittleness, heat generation, low thermal conductivity, and poor surface quality [ 70 , 71 , 72 , 73 ].…”

Section: Non-conventional Finishing Processesmentioning

confidence: 99%

A Review on Surface Finishing Techniques for Difficult-to-Machine Ceramics by Non-Conventional Finishing Processes

et al. 2022

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Ceramics are advanced engineering materials in which have been broadly used in numerous industries due to their superior mechanical and physical properties. For application, the industries require that the ceramic products have high-quality surface finishes, high dimensional accuracy, and clean surfaces to prevent and minimize thermal contact, adhesion, friction, and wear. Ceramics have been classified as difficult-to-machine materials owing to their high hardness, and brittleness. Thus, it is extremely difficult to process them with conventional finishing processes. In this review, trends in the development of non-conventional finishing processes for the surface finishing of difficult-to-machine ceramics are discussed and compared to better comprehend the key finishing capabilities and limitations of each process on improvements in terms of surface roughness. In addition, the future direction of non-conventional finishing processes is introduced. This review will be helpful to many researchers and academicians for carrying out additional research related to the surface finishing techniques of ceramics for applications in various fields.

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“…The cutting of titanium alloys is accompanied by temperature increase in the cutting zone, adhesion, welding and sticking of the chips to the insert, increased tool wear, which negatively affects the process productivity, the quality machined surface, etc. [2,7]. This is especially important when processing extended precision plane surfaces can be conjugated, and which are often machined by a face milling.…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness of Parts Made Titanium Alloys Machined With Face Mill of Original Construction

Hlembotska

Melnyk

2019

Technology transfer: fundamental principles and innovative tech

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Importance of the use of titanic alloys is shown in many industries of engineer. Problems which arise at their processing are described that negatively affect process productivity and indicators of surface quality and etc. This is especially important when machining plane surfaces of parts by face milling. The surface roughness depends first of all on geometrical parameters and the shape of the cutting edge of the tool insert that contacts the processed surface. Therefore it was developed an original design of face mill with a stepped insert arrangement with a cylindrical front surface, and at the same time process productivity was improved. Expediency of use of the proposed design of a face mill it is proved by comparative experimental studies of influence of a form of a front surface of round inserts on roughness of the machined surface of parts from titanium alloy VT1-0. The comparison was made between the machining of the face mill with a cylindrical front insert surface and a standard face mill with round inserts (ISO 6462:2011). A non-composite second-order plan was received results of the study were obtained for the conditions of machining titanium alloy. The profile of the machined surface was investigated to evaluate the roughness Ra and it was determined that, with the maximum cutting modes, the face mill of the original design provided a lower roughness of the machined surface than a standard mill. The optimum cutting modes are determined by the criterion of the roughness of the machined surface of parts made of titanium alloy VT1-0 and the process productivity of face milling. The proposed face mill provides a 1.26 time increase in productivity compared to machining a standard face mill while obtaining minimal roughness.

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Machining of Difficult-To-Cut Materials

Cited by 8 publications

References 20 publications

Optimizing machining efficiency: a comprehensive study on PVD cathodic arc evaporation coated turning tool inserts with TiAlN/AlCrN multilayer coatings

Optimizing machining efficiency: a comprehensive study on PVD cathodic arc evaporation coated turning tool inserts with TiAlN/AlCrN multilayer coatings

A Review on Surface Finishing Techniques for Difficult-to-Machine Ceramics by Non-Conventional Finishing Processes

Surface Roughness of Parts Made Titanium Alloys Machined With Face Mill of Original Construction

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