On dry machining of AZ31B magnesium alloy using textured cutting tool inserts

Magnesium alloys have many advantages as lightweight materials for engineering applications,especially in the fields of automotive and aerospace.They undergo extensive cutting or machining while making products out of them.Dry cutting,a sustainable machining method,causes more friction and adhesion at the tool-chip interface.One of the promising solutions to this problem is cutting tool surface texturing,which can reduce tool wear and friction in dry cutting and improve machining performance.This paper aims to investigate the impact of dimple textures(made on the flank face of cutting inserts)on tool wear and chip morphology in the dry machining of AZ31B magnesium alloy.The results show that the cutting speed was the most significant factor affecting tool flank wear,followed by feed rate and cutting depth.The tool wear mechanism was examined using scanning electron microscope(SEM)images and energy dispersive X-ray spectroscopy(EDS)analysis reports,which showed that at low cutting speed,the main wear mechanism was abrasion,while at high speed,it was adhesion.The chips are discontinuous at low cutting speeds,while continuous at high cutting speeds.The dimple textured flank face cutting tools facilitate the dry machining of AZ31B magnesium alloy and contribute to ecological benefits.

Age Strengthening of Grey Cast Iron Alloys for Machine Cutting Tools Production

This work was carried out with the aim of using alloying and ageing processes to develop new alloys from grey cast iron that will have optimum properties suitable for the manufacturing of machine cutting tools. Four different alloys of grey cast iron with alloying composition of Fe-3% Al-2.5% Cr-2% Mo;Fe-3% Al-2% Cr-2% Mo;Fe-3% Al-2.5% Cr-1.5% Mo and Fe-3% Al-1.5% Cr-2% Mo were produced. The chemical analysis of both as-received base metal and produced alloys was determined using Spetro-CJRO Arc-Spectrometer. The microstructural properties and mechanical properties (hardness, impact toughness and ultimate tensile strength) of the produced alloys were determined for both as-cast samples and aged samples. The results showed that the addition of these alloying elements slightly decreased carbon, silicon and phosphorus content and thereby changed the hypereutectic cast iron to hypoeutectic by reducing the carbon equivalent. Also the morphology of graphite flake was changed as a result of the formation of nitrides and carbides of different phases. The results of the mechanical properties showed that the maximum hardness values obtained for each of the four alloys produced and aged at 300?C are 71.5 HRc, 69 HRc, 66.5 HRc and 65.4 HRc respectively. The maximum values for impact toughness obtained for each of the same produced alloys are 66 J, 63.6 J, 62 J and 60.3 J respectively. Also the maximum ultimate tensile strength values obtained for each of the alloys are 1380 N·mm-2, 1311 N·mm-2, 1260 N·mm-2 and 1190 N·mm-2. Comparing the properties obtained from the produced alloys with those of the commercial cutting tools, it was found that cutting tools manufactured from these produced alloys can compete favourably with cast cobalt tool, high speed steel (HSS) and tool steel.

INFLUENCE OF COLD NITROGEN GAS AND OIL MIST IN MACHINING NICKEL-BASE K424 ALLOY WITH CERAMIC CUTTING TOOLS

The role of cold nitrogen gas and oil mist on tool wear and surface roughness is investigated in turning the K424 nickel-base super alloy with Sialon and SiC whisker-reinforced alumina ceramic tools. A new cooling system is developed and used to lower the temperature of the compressed nitrogen gas. Experiments are performed in three different cooling/lubrication modes, i.e. the dry cutting, the cold nitrogen gas （CNG）, and the cold nitrogen gas and oil mist （CNGOM）. Experimental results show that the depth-of-cut notching severely limits the tool life in all the cooling/lubrication modes. Compared with the dry cutting, the use of CNG and CNGOMcan yield higher wear rate of depth-of-cut notching and worse surface finish.

Smart Cutting Tools and Smart Machining: Development Approaches, and Their Implementation and Application Perspectives

Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts. This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo （FTS） and smart collets for ultra- precision and micro manufacturing purposes. Implemen- tation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Furthermore, implementation tech- niques are presented focusing on： （a） plug-and-produce design principle and the associated smart control algo- rithms, （b） piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, （c） critical cutting temperature control in real-time machining, （d） in- process calibration through machining trials, （e） FE-based design and analysis of smart cutting tools, and （f） applica- tion exemplars on adaptive smart machining.

Improvement Properties of the Cutting Tools Using Technical Plasma Treatment

In spite of the considerable progress made in the domain of the sciences of materials, cutting tools subjected to an intense abrasive wear and a very high temperature of edge. They record during their use an reduced working life. The operations of machining on lathe are regularly stopped for replacing these tools, which influences enormously the production process. Indeed, the search the new materials of substitution, remain a domain very coveted, owing to the fact, it belongs to one stake very significant industrial, in particular, in the mechanical domain and its varied sectors. The recourse to the thermal treatments traditional, limiting in an interval, reduces the wear and the excessive consumption of these cutting tools, but the principal concern of the experts and researchers, in the domain of the mechanical engineering, remain posed. The goal of this study is the introduction of the technique of plasmas, as physical phenomenon, for making material of coating at base of titanium nitrides doped at iron, at the different concentrations. To this objective, one magnetron sputtering with plasma was used for the realization of the coatings deposed on the active parts of the cutting tools. During the experimentation, it was noted that the cutting tools which are treated by plasma, subjected to the machining operations on lathe and the hardness tests, presents one improvement of their hardness and a remarkable increase in their lifespan.

Approach for Polishing Diamond Coated Complicated Cutting Tool: Abrasive Flow Machining(AFM)

Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance

Advances in micro cutting tool design and fabrication

Microcutting is a precision technology that offers flexible fabrication of microfeatures or complex three-dimensional components with high machining accuracy and superior surface quality.This technology may offer great potential as well as advantageous process capabilities for the machining of hard-to-cut materials,such as tungsten carbide.The geometrical design and dimension of the tool cutting edge is a key factor that determines the size and form accuracy possible in the machined workpiece.Currently,the majority of commercial microtools are scaled-down versions of conventional macrotool designs.This approach does not impart optimal performance due to size effects and associated phenomena.Consequently,in-depth analysis and implementation of microcutting mechanics and fundamentals are required to enable successful industrial adaptation in microtool design and fabrication methods.This paper serves as a review of recent microtool designs,materials,and fabrication methods.Analysis of tool performance is discussed,and new approaches and techniques are examined.Of particular focus is tool wear suppression in the machining of hard materials and associated process parameters,including internal cooling and surface patterning techniques.The review concludes with suggestions for an integrated design and fabrication process chain which can aid industrial microtool manufacture.

Research and Development of Ceramic Cutting Tools in China

The research and development of various classes of ceramic cutting tools in China are described,because manufacturing efficiency is fundamental to the growth of China's economy.

Synergistically Toughening Effect of SiC Whiskers and Nanoparticles in Al_2O_3-based Composite Ceramic Cutting Tool Material

In recent decades, many additives with different characteristics have been applied to strengthen and toughen Al2O3-based ceramic cutting tool materials. Among them, SiC whiskers and SiC nanoparticles showed excellent performance in improving the material properties. While no attempts have been made to add SiC whiskers and SiC nanoparticles together into the ceramic matrix and the synergistically toughening effects of them have not been studied. An Al2O3-SiCw-SiC np advanced ceramic cutting tool material is fabricated by adding both one-dimensional SiC whiskers and zero-dimensional SiC nanoparticles into the Al2O3 matrix with an effective dispersing and mixing process. The composites with 25 vol% SiC whiskers and 25 vol% SiC nanoparticles alone are also investegated for comparison purposes. Results show that the Al2O3-SiCw-SiCnp composite with both 20 vo1% SiC whiskers and 5 vol% SiC nanoparticles additives have much improved mechanical properties. The flexural strength of Al2O3-SiCw-SiCnp is 730＋ 95 MPa and fracture toughness is 5.6 ± 0.6 MPa.m1/2. The toughening and strengthening mechanisms of SiC whiskers and nanoparticles are studied when they are added either individually or in combination. It is indicated that when SiC whiskers and nanoparticles are added together, the grains are further refined and homogenized, so that the microstructure and fracture mode ratio is modified. The SiC nanoparticles are found helpful to enhance the toughening effects of the SiC whiskers. The proposed research helps to enrich the types of ceramic cutting tool and is benefit to expand the application range of ceramic cutting tool.

Image Processing Tool Promoting Decision-Making in Liver Surgery of Patients with Chronic Kidney Disease

Preoperative assessment of the liver volume and function of the remnant liver is a mandatory prerequisite before performing major hepatectomy. The aim of this work is to develop and test a software application for evaluation of the residual function of the liver prior to the intervention of the surgeons. For this purpose, a complete software platform consisting of three basic modules: liver volume segmentation, visualization, and virtual cutting, was developed and tested. Liver volume segmentation is based on a patient examination with non-contrast abdominal Computed Tomography (CT). The basis of the segmentation is a multiple seeded region growing algorithm adapted for use with CT images without contrast-enhancement. Virtual tumor resection is performed interactively by outlining the liver region on the CT images. The software application then processes the results to produce a three-dimensional (3D) image of the “resected” region. Finally, 3D rendering module provides possibility for easy and fast interpretation of the segmentation results. The visual outputs are accompanied with quantitative measures that further provide estimation of the residual liver function and based on them the surgeons could make a better decision. The developed system was tested and verified with twenty abdominal CT patient sets consisting of different numbers of tomographic images. Volumes, obtained by manual tracing of two surgeon experts, showed a mean relative difference of 4.5%. The application was used in a study that demonstrates the need and the added value of such a tool in practice and in education.

An Experimental Study of Cutting Performance of Ti(C, N) Based Cermet Cutting Tool

Through systematic cutting experiments, characteristics of the cutting performance of Ti(C, N) based cermets is identified. The experiments were designed to study their resistance,toughness, cutting force, tool-chip friction coefficient and machining quality by comparing them with those of WC based cemented carbides. The cutting data and the regressed empirical formulae would be useful to promote proper application of cermet cutting tool materials.

Machinability of Hastelloy C-276 Using Hot-pressed Sintered Ti(C_7N_3)-based Cermet Cutting Tools

C-276 nickel-based alloy is a difficult-to-cut material. In high-speed machining of Hastelloy C-276, notching is a prominent failure mode due to high mechanical properties of work piece, which results in the short tool life and low productivity. In this paper, a newly developed Ti（C7N3）-based cermet insert manufactured by a hot-pressing method is used to machine the C-276 nickel-based alloy, and its cutting performances are studied. Based on orthogonal experiment method, the influence of cutting parameters on tool life, material removal rates and surface roughness are investigated. Experimental research results indicate that the optimal cutting condition is a cutting speed of 50 m/min, depth of cut of 0.4 mm and feed rate of 0.15 mm/r if the tool life and material removal rates are considered comprehensively. In this case, the tool life is 32 min and material removal rates are 3000 mm^3/min, which is appropriate to the rough machining. If the tool life and surface roughness are considered, the better cutting condition is a cutting speed of 75 m/min, depth of cut of 0.6 mm and feed rate of 0.1 mm/r. In this case, the surface roughness is 0.59μm. Notch wear, flank wear, chipping at the tool nose, built-up edge（BUE） and micro-cracks are found when Ti（C7N3）-based cermet insert turned Hastelloy C-276. Oxidation, adhesive, abrasive and diffusion are the wear mechanisms, which can be investigated by the observations of scanning electron microscope and energy-dispersive spectroscopy. This research will help to guide studies on the evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy C-276 machining.

The Effect of Tool Construction and Cutting Parameters on Surface Roughness and Vibration in Turning of AISI 1045 Steel Using Taguchi Method

This paper presents an experimental investigation focused on identifying the effects of cutting conditions and tool construction on the surface roughness and natural frequency in turning of AISI1045 steel. Machining experiments were carried out at the lathe using carbide cutting insert coated with TiC and two forms of cutting tools made of AISI 5140 steel. Three levels for spindle speed, depth of cut, feed rate and tool overhang were chosen as cutting variables. The Taguchi method L9 orthogonal array was applied to design of experiment. By the help of signal-to-noise ratio and analysis of variance, it was concluded that spindle speed has the significant effect on the surface roughness, while tool overhang is the dominant factor affecting natural frequency for both cutting tools. In addition, the optimum cutting conditions for surface roughness and natural frequency were found at different levels. Finally, confirmation experiments were conducted to verify the effectiveness and efficiency of the Taguchi method in optimizing the cutting parameters for surface roughness and natural frequency.

Prediction of Wearing of Cutting Tools Using Real Time Machining Parameters and Temperature Using Rayleigh-Ham Method

Wear of cutting tools is a big concern for industrial manufacturers, because of their acquisition cost as well as the impact on the production lines when they are unavailable. Law of wear is very important in determining cutting tools lifespan, but most of the existing models don’t take into account the cutting temperature. In this work, the theoretical and experimental results of a dynamic study of metal machining against cutting temperature of a treated steel of grade S235JR with a high-speed steel tool are provided. This study is based on the analysis of two complementary approaches, an experimental approach with the measurement of the temperature and on the other hand, an approach using modeling. Based on unifactorial and multifactorial tests (speed of cut, feed, and depth of cut), this study allowed the highlighting of the influence of the cutting temperature on the machining time. To achieve this objective, two specific approaches have been selected. The first was to measure the temperature of the cutting tool and the second was to determine the wear law using Rayleigh-Ham dimensional analysis method. This study permitted the determination of a law that integrates the cutting temperature in the calculations of the lifespan of the tools during machining.

Mathematical Modelling of Cutting Force as the Most Reliable Information Bearer on Cutting Tools Wearing Phenomenon

Being one of their prominent exploitative characteristics, cutting tools durability depends on the character, intensity and the speed of wearing. Identification of tool wearing is of great significance for the purpose of avoiding sooner or later replacement of tools. The parameters of tool wearing can be measured by out-process and in-process-measuring systems. Given the extremely limiting role of the former in modern production lines, development of the latter （the indirect measuring systems） has gained prominence, The basis of indirect measuring systems comprises a set of various signals originating from the units of the system under treatment which stand in certain correlations with the wearing parameters. The paper presents mathematical models of axial force designed on the basis of experimental research in drilling tempered steel by twist drills made of high-speed steel manufactured by powder metallurgy.

Dynamic Reliability Sensitivity of Cemented Carbide Cutting Tool

Influence of geometric and cutting parameters of cemented carbide cutting tool on reliability of cutting tool has become more and more mature, yet influence of its physical and material parameters on reliability is still blank. In view of this, cutting test and fatigue crack growth test of YT05 cemented carbide cutting tool are conducted to measure such data as the original crack size, growth size, times of impact loading, number and time of cutting tool in failure, and stress distribution of cutting tool is also obtained by simulating cutting process of tools. Mathematical models on dynamic reliability and dynamic reliability sensitivity of cutting tool are derived respectively by taking machining time and times of impact loading into account, thus change rules of dynamic reliability sensitivity to physical and material parameters can be obtained. Theoretical and experimental results show that sensitive degree on each parameter of tools increases gradually with the increase of machining time and times of impact loading, especially for parameters such as fracture toughness, shape parameter, and cutting stress. This proposed model solves such problems as how to determine the most sensitive parameter and influence degree of physical parameters and material parameters to reliability, which is sensitivity, and can provide theoretical foundation for improving reliability of cutting tool system.

High-Speed Machining of Malleable Cast Iron by Various Cutting Tools Coated by Physical Vapor Deposition

The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron.However,the machining adaptability of various coating materials to malleable cast iron has been insufficiently researched.In this paper,turning tests were conducted on cemented carbide tools with different coatings(a thick TiN/TiAlN coating,a thin TiN/TiAlN coating,and a nanocomposite(nc)TiAlSiN coating).All coatings were applied by physical vapor deposition.In a comparative study of chip morphology,cutting force,cutting temperature,specific cutting energy,tool wear,and surface roughness,this study analyzed the cutting characteristics of the tools coated with various materials,and established the relationship between the cutting parameters and machining objectives.The results showed that in malleable cast iron machining,the coating material significantly affects the cutting performance of the tool.Among the three tools,the nc-TiAlSiN-coated carbide tool achieved the minimum cutting force,the lowest cutting temperature,least tool wear,longest tool life,and best surface quality.Moreover,in comparisons between cemented-carbide and compacted-graphite cast iron machined under the same conditions,the wear mechanism of the coated tools was found to depend on the cast iron being machined.Therefore,the performance requirements of a tool depend on multiple factors,and selecting an appropriately coated tool for a particular cast iron material is essential.

Single Point Cutting Tool Fault Diagnosis in Turning Operation Using Reduced Error Pruning Tree Classifier

Tool wear is inevitable in daily machining process since metal cutting process involves the chip rubbing the tool surface after it has been cut by the tool edge.Tool wear dominantly influences the deterioration of surface finish,geometric and dimensional tolerances of the workpiece.Moreover,for complete utilization of cutting tools and reduction of machine downtime during the machining process,it becomes necessary to understand the develop-ment of tool wear and predict its status before happening.In this study,tool condition monitoring system was used to monitor the behavior of a single point cutting tool to predict flank wear.A uniaxial accelerometer was attached to a single point cutting tool under study.The accelerometer acquires vibrational signals during turning operation on a lathe machine.The acquired signals were then used to extract statistical features such as standard error,variance,skewness,etc.The substantial features were recognized to reduce the utilization of computing resources.They were used to classify the signals as good and three different measures of flank wear by a decision tree algorithm.Frequency domain features were also extracted and shown to be less effective in classification in comparison to statistical features.REPTree(Reduced Error Pruning Tree)algorithm was used in this study.REPTree decision tree algorithm achieved a maximum classification accuracy of 72.77%for all signals combined.When spindle speed and feed rate are considered as the variables the accuracy is about 86.25%.When spindle speed is the only variable parameter the accuracy is about 82.71%.When depth of cut,feed rate and speed of the spindle are considered as variable parameters,the accuracy of the decision tree is around 93.51%.This study demonstrates the performance of REPTree classifier in tool condition monitoring.It can be utilized for tool wear identification and thus improve surface finish,dimensional accuracy of the work piece and reduce machine down-time.Any additional research on the work may involve analysis of different classifier algorithms which could potentially predict tool wear with greater accuracy.

生长激素信号肽可诱导重组蛋白外分泌表达

Signal peptide capable of efficiently directing many protein secretion in mammalian cells is one of the key elements in recombinant protein production,gene therapy and the development of DNA vaccines.In order to explore the possibility of rat growth hormone signal peptide as such an element,a new vector based on the mammalian expression vector pcDNA3 was constructed by employing rat growth hormone(rGH) signal peptide as leading sequence,followed by multiple cloning sites,the myc epitope-tag and 6×his purification tag in the expression cassette.The vector was validated by successfully expressing and secretion of chick MMP-2 C-terminal PEX domain,a potential angiogenesis inhibitor,and tandem peptide repeats of myc epitope-tag in COS-7 cells.These results suggest that rat growth hormone signal peptide is effective in the mediation of recombinant protein expression and secretion,and this vector provides a new tool for universal cloning and secretion of exogenous proteins in mammalian cells.