Study of cutting forces on machinability properties of gray cast iron using new ceramics cutting tools

During gray cast iron cutting, the great rate of mechanical energy from cutting forces is converted into heat. Considerable heat is generated, principally in three areas: the shear zone, rake face and at the clearance side of the cutting edge. Excessive heat will cause undesirable high temperature in the tool which leads to softening of the tool and its accelerated wear and breakage. Nowadays the advanced ceramics are widely used in cutting tools. In this paper a composition special of Si3N4 was sintering, characterized, cut and ground to make SNGN120408 and applyed in machining gray cast iron with hardness equal 205 HB in dry cutting conditions by using digital controlled computer lathe. The tool performance was analysed in function of cutting forces, flank wear, temperature and roughness. Therefore metal removing process is carried out for three different cutting speeds (300 m/min, 600 m/min, and 800 m/min), while a cutting depth of 1 mm and a feed rate of 0.33 mm/rev are kept constant. As a result of the experiments, the lowest main cutting force, which depends on cutting speed, is obtained as 264 N at 600 m/min while the highest main cutting force is recorded as 294 N at 300 m/min.

Cutting performance of diamond coated Si3N4 tool during turning

Silicon nitride cutting tools have been used successfully for machining hard materials, like: cast irons, nickel based alloys, etc. However these cutting tools with diamond coating present little information on dry turning operations of gray cast iron. In the present work, Si3N4 square inserts was developed, characterized and subsequently coated with diamond for dry machining operations on gray cast iron. All experiments were conducted with replica. It was used a 1500, 3000, 4500 m cutting length, feed rate of 0.33 mm/rev and keeping the depth of cut constant and equal to 1 mm. The results show that wear in the tool tips of the Si3N4 inserts, in all cutting conditions, was caused by both mechanical and chemical processes. To understand the tool wear mechanisms, a morphological analysis of the inserts, after experiments, has been performed by SEM and optical microscopy. Diamond coated PVD inserts showed to be capable to reach large cutting lengths when machining gray cast iron. © (2010) Trans Tech Publications.

Surface amorphization in diamond turning of silicon crystal investigated by transmission electron microscopy

Silicon crystal exhibits a ductile regime during machining prior to the onset of fracture when appropriate cutting conditions are applied. The present study shows that the ductile regime is a result of a phase transformation which is indirectly evidenced by the amorphous phase detected in the machined surface. Transmission electron microscopy (TEM) planar view studies were successfully performed on monocrystalline silicon (1 0 0) single point diamond turned. TEM electron diffraction patterns show that the machined surface presents diffuse rings along with traces of crystalline material. This is attributed to crystalline silicon immersed in an amorphous matrix. Furthermore, only diffuse rings in the diffraction patterns of the ductile chip are detected, indicating that it is totally amorphous. © 2000 Elsevier Science B.V. All rights reserved.

Estudo comparativo do desempenho de rebolos com grãos superabrasivos e convencionais

Grinding is a precision machining process which is widely used in the manufacture of components requiring fine tolerances and smooth surfaces. There are several imput parameters (cutting conditions, cutting fluid and grinding wheel type used, dressing conditions etc.) which can affect the process variables (tangential and normal cutting forces, roughness, grinding temperatures, G ratio, etc.) leading to differences in the roughness, in the surface integrity and in the mechanical strength of the ground component. Consequently, the imput parameters must be controlled in order to insure the workpiece final quality. This paper presents a comparative evaluation of the performance of two types of grinding wheels [a conventional (Al2O3) and a superabrasive (CBN)] when grinding a VC131 steel, by the analysis of specific process variables when varying the cutting conditions. Highest values of G ratio and lowest workpiece roughness was observed when using CBN grinding wheels. This confirms the global trend of replacement of alumina grinding wheels by CBN, when grinding DTG (difficult to grind) materials.

Estudo da geometria do cavaco no corte com discos abrasivos

This paper shows a research about the study of the chip's geometry generated in the diving cut-off operation, under several cutting conditions. As a result it was possible to verify tint the cutting conditions and the type of the material being cut can directly affect the chip's geometry.

Transverse cylindrical grinding of a eutectic alloy

We report herein on a comparison of the performance of two different grinding wheels (conventional and CBN) in the transverse cylindrical grinding of a eutectic alloy. Three cutting conditions were tested: rough, semi-finishing and finishing. The parameters of evaluation were the cutting force, roughness and wheel wear. The optimal cutting force and roughness values were obtained when grinding with the conventional wheel, due to the superior dressing operation performed under every cutting condition tested. Although the CBN wheel presented the best G ratio values, they were lower than expected owing to the inappropriate dressing operation applied. Excessive wheel corner wear was detected in both wheels, caused by the grinding kinematics (transverse grinding) employed. In terms of cutting force and roughness, the conventional wheel proved to be the better choice under the conditions tested. However, in terms of the G ratio, a cost analysis is crucial to determine whether the differences between the wheels justify the use of the CBN wheel, in which case the dressing operation requires improvement.

Evaluation of the performance of α-SiAlON tool when turning Ti-6Al-4V alloy without coolant

Due to their high hardness and wear resistance, Si3N4 based ceramics are one of the most suitable cutting tool materials for machining cast iron, nickel alloys and hardened steels. However, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. This necessitates a process optimization when machining superalloys with Si3N4 based ceramic cutting tools. The tools are expected to withstand the heat and pressure developed when machining at higher cutting conditions because of their high hardness and melting point. This paper evaluates the performance of α-SiAlON tool in turning Ti-6Al-4V alloy at high cutting conditions, up to 250 m min-1, without coolant. Tool wear, failure modes and temperature were monitored to access the performance of the cutting tool. Test results showed that the performance of α-SiAl0N tool, in terms of tool life, at the cutting conditions investigated is relatively poor due probably to rapid notching and excessive chipping of the cutting edge. These facts are associated with adhesion and diffusion wear rate that tends to weaken the bond strength of the cutting tool.

Proposta de uma máquina para processo de abrasão baseado na combinação de algumas características da lapidação e retificação

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Avaliação da usinabilidade do aço inoxidável martensítico AISI 410

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Efeito do fresamento com alta velocidade de corte na integridade superficial de aços ferríticos com grãos ultrafinos

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Modelagem térmica para avaliação da temperatura no fresamento de aços para moldes e matrizes

Pós-graduação em Engenharia Mecânica - FEIS

Redes neurais: aplicação no monitoramento da vida de ferramentas de corte

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Monitoramento da dressagem do processo de retificação

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Avaliação energética e custo de produção da cana–de açúcar (Saccharum) do preparo de solo ao 5ºcorte

Pós-graduação em Agronomia (Energia na Agricultura) - FCA

Aspectos da furação do titânio 6Al4V com broca de aço rápido sinterizado e broca de metal duro

Pós-graduação em Engenharia Mecânica - FEG