Survival life analysis applied to tool life estimation with variable cutting conditions when machining titanium metal matrix composites (Ti-MMCs)

Aramesh, Maryam; Shaban, Yasser; Yacout, Soumaya; Attia, Helmi; Kishawy, Hossam A.; Balazinski, Marek

doi:10.1080/10910344.2015.1133916

Cited by 26 publications

(11 citation statements)

References 16 publications

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“…Figure 4 shows how the initial progression of tool wear for both lubrication conditions increased with the increasing cutting speed, this being the factor that has the greatest impact. This corresponds to the theory of metal cutting [18], where it is observed that the cutting tool wear is lower during machining using the MQL.…”

Section: Study Of the Initial Progression Of The Cutting Tool Wearsupporting

confidence: 75%

“…There is a direct relationship between the parameters of the cutting regime and the behavior of the initial wear of the cutting tool, alongside its useful life. However, this singularity has received less attention compared to the other two regions of the wear curve [17,18]. At the same time, to evaluate this initial wear of the tool, it is necessary to apply multi-objective optimization [19] of the parameters of the cutting regime [20] in order to reduce its effects.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of the Cutting Regime in the Turning of the AISI 316L Steel for Biomedical Purposes Based on the Initial Progression of Tool Wear

Risco-Alfonso

Pérez‐Rodríguez

Zambrano‐Robledo

et al. 2021

Metals

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The development of biomedical devices has improved the quality of life for millions of people. The increase in life expectancy generates an increase in the demand for these devices. One of the most used materials for these purposes is 316 L austenitic stainless steel due to its mechanical properties and good biocompatibility. The objective of the present investigation was to identify the dependence between the main cutting force, the initial speed of the tool wear, the surface roughness, and the parameters of the cutting regime. Based on these dependencies, a multi-objective optimization model is proposed to minimize the energy consumed and initial wear rate, as well as to maximize productivity, maintaining the surface roughness values below those established by the ISO 5832-1 standard. The wear of the cutting tool was measured on a scanning electron microscope. For the optimization process, a genetic algorithm based on NSGA-II (Non-nominated Sorting Genetic Algorithm) was implemented. The input variables were the cutting speed and the feed in three levels. The cutting force and surface roughness were set as restrictions. It is concluded that the mathematical model allows for the optimization of the cutting regime during dry turning and with the use of MQL (Minimum Quantity Lubrication) with BIDEMICS JX1 ceramic tools (NTK Cutting Tools, Wixom, MI, USA), of AISI 316 L steel for biomedical purposes. Pareto sets and boundaries allow for choosing the most appropriate solution according to the specific conditions of the workshop where it is applied, minimizing the initial progression of tool wear and energy consumed, and maximizing productivity by guaranteeing the surface roughness values established for these types of parts according to the standard.

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Section: Study Of the Initial Progression Of The Cutting Tool Wearsupporting

confidence: 75%

Section: Introductionmentioning

confidence: 99%

Optimization of the Cutting Regime in the Turning of the AISI 316L Steel for Biomedical Purposes Based on the Initial Progression of Tool Wear

Risco-Alfonso

Pérez‐Rodríguez

Zambrano‐Robledo

et al. 2021

Metals

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“…The noise data is the logarithmic value of the sound pressure relative to ambient atmospheric pressure at 20 µPa (micro-pascals). This relationship is shown in Equation (1).…”

Section: Methodsmentioning

confidence: 99%

“…Inaccurate predictions of tool life may result in the rejection of parts, rough surface finish, and tool breakage due to large forces [1]. To reduce unnecessary expenses and tool wear, monitoring the tool condition over its operation is important.…”

Section: Introductionmentioning

confidence: 99%

Understanding Acoustic Emission for Different Metal Cutting Machinery and Operations

Nikhare

Conklin

Loker

2017

JMMP

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Abstract:Machining is one of the major manufacturing techniques where the material is removed to prepare the complete or sub-part. In general, this is also referred to as subtractive manufacturing. Due to solid-to-solid contact between the cutting tool and the work-piece, the machine dynamics get influenced by various operating parameters. This generates force and vibration, and thus noise. Over time the cutting tool reaches its end-of-life which increases the force to cut, and thus produces more vibration and noise. The noise parameter was considered in this work. A 32-element spherical microphone array acoustic camera system was used to record and analyze the sound that was emitted during the machining processes. The startup, idle, and load operating characteristics for various industrial machining equipment were monitored with the acoustic beam former microphone system. The industrial applications included a bench grinder, surface grinder, vertical band saw, lathe machine, and vertical milling machine. Analysis of the acoustic noise generated from these processes could demonstrate the similarities between the cyclical patterns of resonating sound.

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“…Still, adequate knowledge on the wear modes and morphology, as well as factors governing elevated initial tool wear morphology and size in machining hard to cut materials, are still demanded in wider scopes. In this regards, having a precise insight into the initial tool wear mechanism, morphology, and influencing parameters on initial tool wear size may result in better control and optimization of the machining process, and thus, extending tool life when machining hard-to-cut materials such as Ti-MMC [13][14][15][16]. Therefore, within the first seconds of the machining operation, it is strongly recommended to study the initial tool wear mechanisms.…”

Section: Experimental Planmentioning

confidence: 99%

Study of the Effects of Initial Cutting Conditions and Transition Period on Ultimate Tool Life when Machining Inconel 718

et al. 2021

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Rapid tool wear and limited tool life are major problems when machining Inconel 718, which still need further attention. Amongst the reported strategies, limited studies have been reported on optimizing initial cutting conditions by means of tool life improvement. Therefore, in this work, the tool wear progress and tool life were investigated by varying the initial conditions in the transition period, which was set at four seconds. The transition point was discovered by previous works by the authors. After the transition point, similar cutting conditions were used as the reference condition. The tool wear morphology and size were recorded and analyzed in each condition. It was revealed that applying a lower cutting speed and feed rate in the transition period led to improved tool life as compared to the reference condition. In other words, the use of optimum levels of cutting parameters in the transition period of the cutting process may enhance tool life at higher cutting time. For instance, initial feed rate (0.15 mm/rev) and cutting speed (25 m/min) led to the improvement in the ultimate tool life by about 67% and 50%, respectively. Besides, applying the lower initial cutting speed, i.e., 25 m/min, increased the tool life by about 50% when the insert reached the maximum flank wear (vBmax) of 300 µm in comparison with those at higher initial cutting speeds. This phenomenon may lead to better insight into the effect of the influence of the initial cutting conditions in the transition period on tool life when machining hard-to-cut materials. Moreover, the built-up edge (BUE) was exhibited as the primary wear mode in all cutting conditions.

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Survival life analysis applied to tool life estimation with variable cutting conditions when machining titanium metal matrix composites (Ti-MMCs)

Cited by 26 publications

References 16 publications

Optimization of the Cutting Regime in the Turning of the AISI 316L Steel for Biomedical Purposes Based on the Initial Progression of Tool Wear

Optimization of the Cutting Regime in the Turning of the AISI 316L Steel for Biomedical Purposes Based on the Initial Progression of Tool Wear

Understanding Acoustic Emission for Different Metal Cutting Machinery and Operations

Study of the Effects of Initial Cutting Conditions and Transition Period on Ultimate Tool Life when Machining Inconel 718

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