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Experimentation and Prediction of the Wear of a Cutting Tool in Turning Process

M. Merzoug N. Benamara A. Boulenouar B. Bouchouicha M. Mazari
Archives of Metallurgy and Materials | 2018 | vol. 63 | No 2 | DOI: 10.24425/118975
Keywords turning cutting parameters tool wear surface roughness design of experiments
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Abstract

In the present work, the performance of multilayer coated carbide tool was investigated considering the effect of cutting parameters during turning of 34CrMo4 Low alloy steel. It has high strength and creep strength, and good impact tenacity at low temperature. It can work at –110°C to 500°C. And EN 10083-1 34CrMo4 owns high static strength, impact tenacity, fatigue resistance, and hardenability; without overheating tendencies. The objective functions were selected in relation to the parameters of the cutting process: surface roughness criteria. The correlations between the cutting parameters and performance measures, like surface roughness, were established by multiple linear regression models. Highly significant parameters were determined by performing an Analysis of variance (ANOVA). During the experiments flank wear, cutting force and surface roughness value were measured throughout the tool life. The results have been compared with dry and wet-cooled turning. Analysis of variance factors of design and their interactions were studied for their significance. Finally, a model using multiple regression analysis between cutting speed, fee rate and depth of cut with the tool life was established.
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Authors and Affiliations

M. Merzoug
N. Benamara
A. Boulenouar
B. Bouchouicha
M. Mazari

Multiobjective Performance Investigation of CNT Coated HSS Tool Under the Response Surface Methodology Platform

Chandru Manivannan Selladurai Velappan Venkatesh Chenrayan
Archives of Metallurgy and Materials | 2021 | vol. 66 | No 2 | 627-635 | DOI: 10.24425/amm.2021.135900
Keywords Carbon nanotube RSM cutting forces cutting tooltip temperature tool wear
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Abstract

The present research employs the statistical tool of Response surface methodology (RSM) to evaluate the machining characteristics of carbon nanotubes (CNTs) coated high-speed steel (HSS) tools. The methodology used for depositing carbon nanotubes was Plasma-Enhanced Chemical Vapor Deposition (PECVD). Cutting speed, thickness of cut, and feed rate were chosen as machining factors, and cutting forces, cutting tooltip temperature, tool wear, and surface roughness were included as machining responses. Three-level of cutting conditions were followed. The face-centered, Central Composite Design (CCD) was followed to conduct twenty number of experiments. The speed of cutting and rate of feed have been identified as the most influential variables over the responses considered, followed by the thickness of cut. The model reveals the optimized level of cutting parameters to achieve the required objectives. The confirmation experiments were also carried out to validate the acceptable degree of variations between the experimental results and the predicted one.
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Authors and Affiliations

Chandru Manivannan
1
ORCID: ORCID
Selladurai Velappan
2
ORCID: ORCID
Venkatesh Chenrayan
3
ORCID: ORCID
  1. Dhirajlal Gandhi College of Technology, Salem – 636309, Tamilnadu, India
  2. Coimbatore Institute of Technology, Coimbatore – 641014, Tamilnadu, India
  3. Adama Science and Technology University, Adama, Ethiopia

Evaluation of Adhesive Wear Mechanism for Application in Hybrid Tool Wear Model in Hot Forging Process

M. Wilkus Ł. Rauch D. Szeliga M. Pietrzyk
Archives of Metallurgy and Materials | 2019 | vol. 64 | No 4 | 1395-1402 | DOI: 10.24425/amm.2019.130106
Keywords tool wear adhesion forging wear mechanisms synergetic model
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Abstract

In hot forging process, tool life is an important factor which influences the economy of production. Wear mechanisms in these processes are dependent on each other, so modeling of them is a difficult problem. The present research is focused on development of a hybrid tool wear model for hot forging processes and evaluation of adding adhesive mechanism component to this model. Although adhesive wear is dominant in cases, in which sliding distances are large, there is a group of hot forging processes, in which adhesion is an important factor in specific tool parts. In the paper, a proposed hybrid tool wear model has been described and various adhesive wear models have been reviewed. The feasible model has been chosen, adapted and implemented. It has been shown that adding adhesive wear model increases predictive capabilities of the global hybrid tool wear model as far as characteristic hot forging processes is considered.

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Authors and Affiliations

M. Wilkus
Ł. Rauch
D. Szeliga
M. Pietrzyk

Wear and surface characteristics on tool performance with CVD coating of Al2O3/TiCN inserts during machining of Inconel 718 alloys

Shailesh Rao Agari
Archive of Mechanical Engineering | 2022 | vol. 69 | No 1 | 59-75 | DOI: 10.24425/ame.2021.139647
Keywords chip morphology tool wear surface roughness super alloy - Inconel 717
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Abstract

The Inconel 718 alloys, which are primarily temperature resistant, are widely used in aviation, aerospace and nuclear industries. The study on dry cutting processes for this alloy becomes difficult due to its high hardness and low thermal conductivity, wherein, most of the heat transfers due to friction are accumulated over the tool surface. Further, several challenges like increased cutting force, developing high temperature and rapid tool wear are observed during its machining process. To overcome these, the coated tool inserts are used for machining the superalloys. In the present work, the cemented carbide tool is coated with chemical vapor deposition multi-layering Al 2O 3/TiCN under the dry cutting environment. The machining processes are carried out with varying cutting speeds: 65, 81, 95, and 106 m/min, feed rate 0.1 mm/rev, and depth of cut 0.2 mm. The variation in the cutting speeds can attain high temperatures, which may activate built-up-edge development which leads to extensive tool wear. In this context, the detailed chip morphology and its detailed analysis are carried out initially to understand the machining performance. Simultaneously, the surface roughness of the machined surface is studied for a clear understanding of the machining process. The potential tool wear mechanism in terms of abrasion, adhesion, tool chip off, delaminating of coating, flank wear, and crater wear is extensively identified during the processes. From the results, it is observed that the machining process at 81 m/min corresponds to a better machining process in terms of lesser cutting force, lower cutting temperature, better surface finish, and reduced tool wear than the other machining processes.
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Authors and Affiliations

Shailesh Rao Agari
1
  1. Department of Industrial and Production Engineering, The National Institute of Engineering, Mysuru, Karnataka, India

Wear Mechanisms Analysis of Dies Used in the Process of Hot Forging a Valve Made of High Nickel Steel

M. Hawryluk Z. Gronostajski M. Kaszuba J. Krawczyk P. Widomski J. Ziemba M. Zwierzchowski J. Janik
Archives of Metallurgy and Materials | 2018 | vol. 63 | No 4 | 1963-1974 | DOI: 10.24425/amm.2018.125131
Keywords tool wear tools durability destructive mechanisms valve engine high nickel steel
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Abstract

The study presents a durability analysis of dies used in the first operation of producing a valve-type forging from high nickel steel assigned to be applied in motor truck engines. The analyzed process of producing exhaust valves is realized in the forward extrusion technology and next through forging in closed dies. It is difficult to master, mainly due to the increased adhesion of the charge material (high nickel steel) to the tool’s substrate. The mean durability of tools made of tool steel W360, subjected to thermal treatment and nitriding, equals about 1000 forgings. In order to perform a thorough analysis, complex investigations were carried out, which included: a macroscopic analysis combined with laser scanning, numerical modelling by FEM, microstructural tests on a scanning electron microscopy and light microscopy (metallographic), as well as hardness tests. The preliminary results showed the presence of traces of abrasive wear, fatigue cracks as well as traces of adhesive wear and plastic deformation on the surface of the dies. Also, the effect of the forging material being stuck to the tool surface was observed, caused by the excessive friction in the forging’s contact with the tool and the presence of intermetallic phases in the nickel-chromium steel. The obtained results demonstrated numerous tool cracks, excessive friction, especially in the area of sectional reduction, as well as sticking of the forging material, which, with insufficient control of the tribological conditions, may be the cause of premature wear of the dies.

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Authors and Affiliations

M. Hawryluk
Z. Gronostajski
M. Kaszuba
J. Krawczyk
P. Widomski
J. Ziemba
M. Zwierzchowski
J. Janik

An influence of parameters of micro-electrical discharge machining on wear of tool electrode

Govindan Puthumana
Archive of Mechanical Engineering | 2017 | vol. 64 | No 2 | 149-163 | DOI: 10.1515/meceng-2017-0009
Keywords Micro-EDM tool wear ratio process inputs statistical methods main effects interactions regression analysis
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Abstract

To achieve better precision of features generated using the micro-electrical discharge machining (micro-EDM), there is a necessity to minimize the wear of the tool electrode, because a change in the dimensions of the electrode is reflected directly or indirectly on the feature. This paper presents a novel modeling and analysis approach of the tool wear in micro-EDM using a systematic statistical method exemplifying the influences of capacitance, feed rate and voltage on the tool wear ratio. The association between tool wear ratio and the input factors is comprehended by using main effect plots, interaction effects and regression analysis. A maximum variation of four-fold in the tool wear ratio have been observed which indicated that the tool wear ratio varies significantly over the trials. As the capacitance increases from 1 to 10 nF, the increase in tool wear ratio is by 33%. An increase in voltage as well as capacitance would lead to an increase in the number of charged particles, the number of collisions among them, which further enhances the transfer of the proportion of heat energy to the tool surface. Furthermore, to model the tool wear phenomenon, a egression relationship between tool wear ratio and the process inputs has been developed.

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Authors and Affiliations

Govindan Puthumana
1
  1. Technical University of Denmark, Lyngby, Denmark

Analysis of Results of Non-Contact Coordinate Measurement of a Cutting Tool Applied for Mould Machining

A. Bazan M. Magdziak B. Jamuła
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 121-127 | DOI: 10.24425/afe.2022.143960
Keywords Tool wear monitoring Coordinate measuring technique Non-contact coordinate measurements Accuracy of measurements
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Abstract

One of the main problems of machining of moulds is the need for an effective monitoring system of wear of cutting tools. This paper presents the results of coordinate measurements of a cutting tool which were obtained by using the non-contact measuring system based on the ACCURA II coordinate measuring machine equipped with the LineScan laser measuring probe and the Calypso metrology software. Inves-tigations were carried out for several measurement strategies including different measurement resolutions and scanning speeds. The results of the coordinate measurements obtained by using the above-mentioned coordinate measuring system were compared to the reference data measured by means of the InfiniteFocus microscope. The measurement results were analysed by means of two software packages: Focus Inspection and Zeiss Reverse Engineering. The point clouds measured by using the LineScan probe were characterized by the selected deviation statistics equal to 4-6 μm when a good match between measurement points and the reference data was obtained. Moreover, these statistics mainly depend on the measurement resolution. The results of the performed experimental research allowed for drawing conclusions concerning the significance of the effect of the adopted measurement strategies on the results of the non-contact coordinate measurements of the selected cutting tool. The application of the non-contact coordinate measurements to the above-mentioned measurement task may contribute to the development of regeneration methods for cutting tools applied for mould manufacturing.
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Authors and Affiliations

A. Bazan
1
M. Magdziak
1
B. Jamuła
1
  1. Department of Manufacturing Techniques and Automation, Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland

Comprehensive analysis of tribological factor influence on stress-strain and thermal state of workpiece during titanium alloys machining

Vadym Stupnytskyy Xianning She
Archive of Mechanical Engineering | 2021 | vol. 68 | No 2 | 227-248 | DOI: 10.24425/ame.2021.137049
Keywords titanium alloy cutting coefficient of friction stress-strain state thermal state simulation of cutting tool wear
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Abstract

The article describes how different friction coefficients under certain cutting conditions and parameters affect the formation of the stress-strain and thermal states of the product when titanium alloy machining. A new research methodology is used for the study. Firstly, in the initial data for simulation, each time a different declared coefficient of friction is proposed, and every such task of the cutting process modelling is solved for various cutting parameters. The second stage analyzes how these coefficients influence the stress-strain and thermodynamic state of the workpiece and tool during cutting, as well as the tool wear dynamics. In the third stage of the study, ways for ensuring these analytically-grounded tribological cutting conditions are proposed. The analysis of different wear criteria in the simulation models of titanium alloys cutting is carried out. Experimental studies confirm simulation results.
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Authors and Affiliations

Vadym Stupnytskyy
1
ORCID: ORCID
Xianning She
1
ORCID: ORCID
  1. Lviv Polytechnic National University, Lviv, Ukraine

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