Cutting forces and wear analysis of Si3N4 diamond coated tools in high speed machining

Si3N4 tools were coated with a thin diamond film using a Hot-Filament Chemical Vapour Deposition (HFCVD) reactor, in order to machining a grey cast iron. Wear behaviour of these tools in high speed machining was the main subject of this work. Turning tests were performed with a combination of cutting speeds of 500, 700 and 900 m min−1, and feed rates of 0.1, 0.25 and 0.4 mm rot−1, remaining constant the depth of cut of 1 mm. In order to evaluate the tool behaviour during the turning tests, cutting forces were analyzed being verified a significant increase with feed rate. Diamond film removal occurred for the most severe set of cutting parameters. It was also observed the adhesion of iron and manganese from the workpiece to the tool. Tests were performed on a CNC lathe provided with a 3-axis dynamometer. Results were collected and registered by homemade software. Tool wear analysis was achieved by a Scanning Electron Microscope (SEM) provided with an X-ray Energy Dispersive Spectroscopy (EDS) system. Surface analysis was performed by a profilometer.

Wear of rotary plows operating in a tropical clay loam soil

The wear resistance of rotary plows operating in a clay loam soil was studied. The degree of damage caused to the soil and the amount of mass lost by the tools were determined in order to establish correlations between the physical properties of the soil and the wear mechanisms acting on the tribosystem. Field tests were carried out in 12 plots and a randomized experimental design with 4 levels, 3 replicas per level and 2 passes per plot was applied. The levels relate to the tillage implements employed: rotary tiller, rotary power harrow, small motorized rotary tiller and control (unaltered soil). The highest mass losses were measured in rotary tiller and rotary power harrow's tools, while the small motorized rotary tiller's tools showed generally lower levels of damage. It was determined that the effective contact time between tool and soil, the rotating speed and the sudden impact forces are the most significant factors affecting the wear resistance in field operations. Thirty days after tillage operation the soil samples were taken from each plot at a mean depth of 100 mm in order to determine bulk density, gravimetric moisture content and percentage of aggregates smaller than 5 mm. No significant differences among the values of these properties were found in the experiments. The wear mechanisms acting on the tools' surface are complex and include 2-body and 3-body abrasion as well as the presence of sudden impact forces.

Investigation on diamond turning of silicon crystal - generation mechanism of surface cut with worn tool

This paper discusses the effect of tool wear on surface finish in single-point diamond turning of single crystal silicon. The morphology and topography of the machined surface clearly show the type of cutting edge wear reproduced onto the cutting grooves. Scanning electron microscopy is used in order to correlate the cutting edge damage and microtopography features observed through atomic force microscopy. The possible wear mechanisms affecting tool performance and surface generation during cutting are also discussed. The zero degree rake angle single point diamond tool presented small nicks on the cutting edge. The negative rake angle tools presented more a type of crater wear on the rake face. No wear was detected on flank face of the diamond tools.

Recurrence Quantification Analysis of System Signals for Detecting Tool and Chatter in Turning

In this thesis, the applications of the recurrence quantification analysis in metal cutting operation in a lathe, with specific objective to detect tool wear and chatter, are presented.This study is based on the discovery that process dynamics in a lathe is low dimensional chaotic. It implies that the machine dynamics is controllable using principles of chaos theory. This understanding is to revolutionize the feature extraction methodologies used in condition monitoring systems as conventional linear methods or models are incapable of capturing the critical and strange behaviors associated with the metal cutting process.As sensor based approaches provide an automated and cost effective way to monitor and control, an efficient feature extraction methodology based on nonlinear time series analysis is much more demanding. The task here is more complex when the information has to be deduced solely from sensor signals since traditional methods do not address the issue of how to treat noise present in real-world processes and its non-stationarity. In an effort to get over these two issues to the maximum possible, this thesis adopts the recurrence quantification analysis methodology in the study since this feature extraction technique is found to be robust against noise and stationarity in the signals.The work consists of two different sets of experiments in a lathe; set-I and set-2. The experiment, set-I, study the influence of tool wear on the RQA variables whereas the set-2 is carried out to identify the sensitive RQA variables to machine tool chatter followed by its validation in actual cutting. To obtain the bounds of the spectrum of the significant RQA variable values, in set-i, a fresh tool and a worn tool are used for cutting. The first part of the set-2 experiments uses a stepped shaft in order to create chatter at a known location. And the second part uses a conical section having a uniform taper along the axis for creating chatter to onset at some distance from the smaller end by gradually increasing the depth of cut while keeping the spindle speed and feed rate constant.The study concludes by revealing the dependence of certain RQA variables; percent determinism, percent recurrence and entropy, to tool wear and chatter unambiguously. The performances of the results establish this methodology to be viable for detection of tool wear and chatter in metal cutting operation in a lathe. The key reason is that the dynamics of the system under study have been nonlinear and the recurrence quantification analysis can characterize them adequately.This work establishes that principles and practice of machining can be considerably benefited and advanced from using nonlinear dynamics and chaos theory.

Cutting forces in turning of gray cast iron using silicon nitride based cutting tool

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

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.

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.

Tool Condition Monitoring of Single-Point Dresser Using Acoustic Emission and Neural Networks Models

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

Neural tool condition estimation in the grinding of advanced ceramics

Ceramic parts are increasingly replacing metal parts due to their excellent physical, chemical and mechanical properties, however they also make them difficult to manufacture by traditional machining methods. The developments carried out in this work are used to estimate tool wear during the grinding of advanced ceramics. The learning process was fed with data collected from a surface grinding machine with tangential diamond wheel and alumina ceramic test specimens, in three cutting configurations: with depths of cut of 120 mu m, 70 mu m and 20 mu m. The grinding wheel speed was 35m/s and the table speed 2.3m/s. Four neural models were evaluated, namely: Multilayer Perceptron, Radial Basis Function, Generalized Regression Neural Networks and the Adaptive Neuro-Fuzzy Inference System. The models'performance evaluation routines were executed automatically, testing all the possible combinations of inputs, number of neurons, number of layers, and spreading. The computational results reveal that the neural models were highly successful in estimating tool wear, since the errors were lower than 4%.

The Performance Characteristics of a Surface-Modified Cutting Tool

In the past, many papers have been presented which show that the coating of cutting tools often yields decreased wear rates and reduced coefficients of friction. Although different theories are proposed, covering areas such as hardness theory, diffusion barrier theory, thermal barrier theory, and reduced friction theory, most have not dealt with the question of how and why the coating of tool substrates with hard materials such as Titanium Nitride (TiN), Titanium Carbide (TiC) and Aluminium Oxide (Al203) transforms the performance and life of cutting tools. This project discusses the complex interrelationship that encompasses the thermal barrier function and the relatively low sliding friction coefficient of TiN on an undulating tool surface, and presents the result of an investigation into the cutting characteristics and performance of EDMed surface-modified carbide cutting tool inserts. The tool inserts were coated with TiN by the physical vapour deposition (PVD) method. PVD coating is also known as Ion-plating which is the general term of the coating method in which the film is created by attracting ionized metal vapour in this the metal was Titanium and ionized gas onto negatively biased substrate surface. Coating by PVD was chosen because it is done at a temperature of not more than 5000C whereas chemical Vapour Deposition CVD process is done at very high temperature of about 8500C and in two stages of heating up the substrates. The high temperatures involved in CVD affects the strength of the (tool) substrates. In this study, comparative cutting tests using TiN-coated control specimens with no EDM surface structures and TiN-coated EDMed tools with a crater-like surface topography were carried out on mild steel grade EN-3. Various cutting speeds were investigated, up to an increase of 40% of the tool manufacturer’s recommended speed. Fifteen minutes of cutting were carried out for each insert at the speeds investigated. Conventional tool inserts normally have a tool life of approximately 15 minutes of cutting. After every five cuts (passes) microscopic pictures of the tool wear profiles were taken, in order to monitor the progressive wear on the rake face and on the flank of the insert. The power load was monitored for each cut taken using an on-board meter on the CNC machine to establish the amount of power needed for each stage of operation. The spindle drive for the machine is an 11 KW/hr motor. Results obtained confirmed the advantages of cutting at all speeds investigated using EDMed coated inserts, in terms of reduced tool wear and low power loads. Moreover, the surface finish on the workpiece was consistently better for the EDMed inserts. The thesis discusses the relevance of the finite element method in the analysis of metal cutting processes, so that metal machinists can design, manufacture and deliver goods (tools) to the market quickly and on time without going through the hassle of trial and error approach for new products. Improvements in manufacturing technologies require better knowledge of modelling metal cutting processes. Technically the use of computational models has a great value in reducing or even eliminating the number of experiments traditionally used for tool design, process selection, machinability evaluation, and chip breakage investigations. In this work, much interest in theoretical and experimental investigations of metal machining were given special attention. Finite element analysis (FEA) was given priority in this study to predict tool wear and coating deformations during machining. Particular attention was devoted to the complicated mechanisms usually associated with metal cutting, such as interfacial friction; heat generated due to friction and severe strain in the cutting region, and high strain rates. It is therefore concluded that Roughened contact surface comprising of peaks and valleys coated with hard materials (TiN) provide wear-resisting properties as the coatings get entrapped in the valleys and help reduce friction at chip-tool interface. The contributions to knowledge: a. Relates to a wear-resisting surface structure for application in contact surfaces and structures in metal cutting and forming tools with ability to give wear-resisting surface profile. b. Provide technique for designing tool with roughened surface comprising of peaks and valleys covered in conformal coating with a material such as TiN, TiC etc which is wear-resisting structure with surface roughness profile compose of valleys which entrap residual coating material during wear thereby enabling the entrapped coating material to give improved wear resistance. c. Provide knowledge for increased tool life through wear resistance, hardness and chemical stability at high temperatures because of reduced friction at the tool-chip and work-tool interfaces due to tool coating, which leads to reduced heat generation at the cutting zones. d. Establishes that Undulating surface topographies on cutting tips tend to hold coating materials longer in the valleys, thus giving enhanced protection to the tool and the tool can cut faster by 40% and last 60% longer than conventional tools on the markets today.

Review of Contact and Dynamic Phenomena in Cold Roll Forming

This review reflects the state of the art in study of contact and dynamic phenomena occurring in cold roll forming. The importance of taking these phenomena into account is determined by significant machine time and tooling costs spent on worn out forming rolls replacement and equipment adjustment in cold roll forming. Predictive modelling of the tool wear caused by contact and dynamic phenomena can reduce the production losses in this technological process.

A study of high-speed milling characteristics of nitinol

High-speed milling (HSM) has many advantages over conventional machining. Among these advantages, the lower cutting force associated with the machining process is of particular significance for Nitinol alloys because their machined surfaces show less strain hardening. In this article, a systematic study has been carried out to investigate the machining characteristics of a Ni50.6Ti49.4 alloy in HSM. The effects of cutting speed, feed rate, and depth of cut on machined surface characteristics and tool wear are studied. It is found that an increase in cutting speed has resulted in a better surface finish and less work hardening. This is attributed to the reduction of chip cross-sectional area or chip thickness, which thus leads to a lower cutting force or load.

Emissions of nanoparticles during friction stir welding (FSW) of aluminium alloys

Friction stir welding (FSW) is now well established as a welding process capable of joining some different types of metallic materials, as it was (1) found to be a reliable and economical way of producing high quality welds, and (2) considered a "clean" welding process that does not involve fusion of metal, as is the case with other traditional welding processes. The aim of this study was to determine whether the emission of particles during FSW in the nanorange of the most commonly used aluminum (Al) alloys, AA 5083 and AA 6082, originated from the Al alloy itself due to friction of the welding tool against the item that was being welded. Another goal was to measure Al alloys in the alveolar deposited surface area during FSW. Nanoparticles dimensions were predominantly in the 40- and 70-nm range. This study demonstrated that microparticles were also emitted during FSW but due to tool wear. However, the biological relevance and toxic manifestations of these microparticles remain to be determined.

Preliminary study on the production of functionally graded materials by friction stir processing

Dissertação apresentada na Faculdade de Ciências e Tecnologia da Universidade Nova de Lisboa para obtenção do grau de Mestre em Engenharia Mecânica

M-käsittelyn vaikutus lastuamalla valmistettavan tuotteen valmistuskustannuksiin

Paremmin lastuttavia M-käsiteltyjä teräksiä on käytetty yrityksissä jo yli 20 vuoden ajan. Ominaisuuksiensa ansiosta M-teräksillä on pystytty pienentämään koneistuskustannuksia ja parantamaan kilpailukykyä. Viime vuosien aikana lastuavat terät ja työstökoneet ovat kuitenkin kehittyneet ja ero M-terästen ja tavanomaisten terästen välillä on voinut kaventua. Tämän diplomityön tavoitteena oli tutkia, saavutetaanko M-teräksen käytöllä taloudellisia etuja nykyaikaisissa konepajaolosuhteissa. Tutkimuksessa vertailtiin M-käsitellyn ja tavanomaisen 42CrMo4 – teräksen koneistusta. Valmistuskokeissa tarkasteltiin terien kulumista, lastun muotoa ja pinnanlaatua. Koekappaleena toimi olakkeellinen kuusiomutteri M64 kierteellä. Tuotteita valmistettiin yli 500 kappaletta ja materiaalia poistettiin noin 2000 kg. Koetulosten perusteella tuotteille laskettiin koneistuskustannukset kuvitteellisessa yrityksessä. Ero materiaalien välillä oli suurin työvaiheissa, joissa lastuaminen oli jatkuvaa. Sisä- ja ulkosorvauksessa M-käsiteltyä terästä lastunneiden terien kestoikä oli noin kaksinkertainen ja kierteen sorvauksessa noin nelinkertainen tavalliseen teräkseen verrattuna. Hakkaavassa työstössä terien kestoikä oli molemmilla materiaaleilla sama. Työssä suoritettujen kokeiden ja kustannuslaskelmien perusteella, käyttämällä M-käsiteltyä terästä voidaan pienentää valmistuskustannuksia. Materiaalien välinen ero korostuu, kun hakkaavaa työstöä on vähän, sarjat ovat suuria ja tuotanto on miehittämätöntä.