Wear and failure modes in the bandsawing operation when cutting ball-bearing steel

et al. 2014

IJSURFSE

Self Cite

His research interests include heat treatment of ferrous and non-ferrous alloys, metal machining and surface coatings for protection against wear. Ali Daadbin Ali Daadbin obtained his PhD in the field of Noise & Vibration at University of Birmingham UK in 1983. He worked as Research Associates in University of Newcastle, UK, on different projects with the local industry followed by a lectureship post. Since 1990 he has worked at Northumbria University as Senior Lecturer. During this period he has taken on variety of Research and Consultancy projects in: Vibration Monitoring, Modelling for Stress and Vibration, On-site measurement of stress, Dynamics of High Speed Machinery, Composite Materials and Modelling of scaling of coating in materials, research into special coating of Bandsaw for cutting high performance Titanium alloys, rock Mechanics and continuous monitoring of wind turbines and trains. He is a Fellow of Institution of Mechanical Engineers UK.

Section: Specific Cutting Energymentioning

confidence: 99%

“…), very little or no attention has been paid on primary machining operations (e.g., bandsawing). Owing to the scientific work carried out by several researchers, bandsawing is now a well understood machining operation (Sarwar et al, 2007;Ahmed et al, 1991;Andersson et al, 2001).…”

Section: Introductionmentioning

confidence: 99%

Development of AlTiN coated carbide bandsaw for machining titanium-17 alloy

Khan

Daadbin

et al. 2014

IJSURFSE

Self Cite

“…In general, the principal wear modes in any bandsaw tooth can be identified as flank wear, corner wear and small rake face wear. In High Speed Steel (HSS) bimetal bandsaw tooth, flank and corner wear are developed due to the abrasive action between the tooth and the machined workpiece with small to large amount of adhesive wear depending the properties of the workpiece materials [9,10]. Plastic deformation of the tooth can also be observed at the end of tooth life due to the generation of excessive frictional heat.…”

Section: Wear Modes and Mechanisms In Bandsaw Teethmentioning

confidence: 99%

Material Behavior At The Extreme Cutting Edge In Bandsawing

Sarwar

Haider

AIP Conference Proceedings

et al. 2011

Self Cite

In recent years, bandsawing has been widely accepted as a favourite option for metal cutting off operations where the accuracy of cut, good surface finish, low kerf loss, long tool life and high material removal rate are required. Material removal by multipoint cutting tools such as bandsaw is a complex mechanism owing to the geometry of the bandsaw tooth (e.g., limited gullet size, tooth setting etc.) and the layer of material removed or undeformed chip thickness or depth of cut (5 µm -50 µm) being smaller than or equal to the cutting edge radius (5 µm -15 µm). This situation can lead to inefficient material removal in bandsawing. Most of the research work are concentrated on the mechanics of material removal by single point cutting tool such as lathe tool. However, such efforts are very limited in multipoint cutting tools such as in bandsaw. This paper presents the fundamental understanding of the material behaviour at the extreme cutting edge of bandsaw tooth, which would help in designing and manufacturing of blades with higher cutting performance and life. "High Speed Photography" has been carried out to analyse the material removal process at the extreme cutting edge of bandsaw tooth. Geometric model of chip formation mechanisms based on the evidences found during "High Speed Photography" and "Quick Stop" process is presented. Wear modes and mechanism in bimetal and carbide tipped bandsaw teeth are also presented.

“…In general, abrasion, adhesion, BUE formation, diffusion and cracking were observed the common wear mechanisms in carbide tools during widely used Inconel machining processes such turning 1,5,[16][17][18] , milling 3,10,13,[19][20][21] and drilling 22-24. In contrast to other sawing techniques, bandsawing is widely used in cutting off operations and offer competitive advantages of higher metal removal rate, lower kerf loss, better straightness of cut, competitive surface finish and a longer tool life. A number of scientific studies have been reported in the literature to provide an insight about bandsaw tooth design, mechanics of bandsawing, bandsaw performance and wear modes and mechanisms in bandsaw cutting edges [25][26][27][28] . Majority of these studies were focused on the bandsawing of steel workpieces with bimetal high-speed steel bandsaws 29 .…”

Section: Introductionmentioning

confidence: 99%

Investigating tool performance and wear when simulating bandsawing of nickel-based superalloy under interrupted orthogonal turning condition

Khan

Haider

Proceedings of the Institution of Mechanical Engineers, Part B:

2017

Self Cite

The manufacturing industries still face the most challenging job at hand to machine Nickelbased superalloy, Inconel 718, efficiently and economically. In contrast to the extensive research efforts in secondary machining processes such as turning, milling and drilling, very little or no attention is paid on bandsawing of Inconel 718. The paper presents an experimental investigation of machining Inconel 718 using carbide tipped bandsaw teeth in a custom made experimental facility. Cutting forces were measured during the bandsawing operation using a dynamometer and the wear modes and mechanisms in the bandsaw teeth were investigated in a Scanning Electron Microscope (SEM). Three different feeds or depths of cut (10 μm, 20 μm and 30 μm) were employed with a cutting speed of 30 m/min during the machining tests. At smaller feed or depth of cut (10 μm), abrasive wear, adhesive wear and some degree of plastic deformation were identified as the governing mechanisms of tool wear. The higher depth of cut (30 μm) could cause cracking, chipping or premature failure of the carbide tip in bandsaw tooth. Strong welding of workpiece material to the cutting edge formed a built-up-edge (BUE), which would impair the bandsawability due to the modification of the cutting edge. The higher depth of cut significantly improved the machining performance due to the reduction in specific cutting energy. However, it was not recommended to apply higher depth of cut as there were obvious possibilities of premature tooth failure. Machining force and specific cutting energy results along with chip characteristics were correlated with the tool performance and tool wear. The results of this investigation would be helpful for bandsaw manufacturers and end users to get a fundamental understanding of the bandsawability of Inocnel 718 with the carbide tipped bandsaw.