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.

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.

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.

Wear Patterns and Mechanisms of Cutting Tools in High Speed Face Milling

High speed machining has received an important interest because it leads to an increase of productivity and a better workpiece surface quality. However, at high cutting speeds, the tool wear increases dramatically due to the high temperature at the tool-workpiece interface. Tool wear impairs the surface finish and hence the tool life is reduced. That is why an important objective of metal cutting research has been the assessment of tool wear patterns and mechanisms. In this paper, wear performances of PCBN tool, ceramic tool, coated carbide tool and fine-grained carbide tool in high speed face milling were presented when cutting cast iron, 45# tempered carbon steel and 45# hardened carbon steel. Tool wear patterns were examined through a tool-making microscope. The research results showed that tool wear types differed in various matching of materials between cutting tool and workpiece. The dominant wear patterns observed were rake face wear, flank wear, chipping, fracture and breakage. The main wear mechanisms were mechanical friction, adhesion, diffusion and chemical wear promoted by cutting forces and high cutting temperature. Hence, the important considerations of high speed cutting tool materials are high heat-resistance and wear-resistance, chemical stability as well as resistance to failure of coatings. The research results will be great benefit to the design and the selection of tool materials and control of tool wear in high-speed machining processes.

Precise measurement of geometric and physical quantities in cutting tools inspection and condition monitoring: A review

As one of the most important terminals in machining, cutting tools have been widely used for components manufacturing in aerospace and other industries. The quality of these components and processing efficiency are closely linked to the performance of cutting tools. Therefore, it is essential and critical to inspect the cutting tools and monitor the condition during the stage of manufacturing and machining. This review aims to discuss and summarize the key problems, methods,and techniques from the perspective of the tool geometric and the physical quantities measurement,including machine vision, physical sensors and data processing. It is worth mentioning that we focus on the topic of precision measurement methods and discuss universal solutions by identifying the common characteristics of the measured quantities. Eventually, the challenges and future trends for the development of in-depth research and practical applications are concluded. The research and application of precise measurement techniques for geometric and physical quantities will better promote the development of intelligent manufacturing.

Progress on Bionic Textured Cutting Tools:A Review and Prospects

Cutting tools are known as the“productivity”of the manufacturing industry,which affects the production efficiency and quality of the workpiece,and has become the focus of research and attention in academia and industry.However,traditional cutting tools often suffer from adhesion or wear during the cutting process,which considerably reduces the cutting efficiency and service life of the tools,and makes it difficult to meet current production requirements.To solve the above problems,scholars have introduced bionics into the tool’s design,applying the microscopic structure of the biological surface to the tool surface to alleviate the tool’s failure.This paper mainly summarizes the research progress of bionic textured cutting tools.Firstly,categorize whether the bionic texture design is inspired by a single organism or multiple organisms.Secondly,it is discussed that the non-smooth surface of the biological surface has five characteristics:hydrophilic lubricity,wear resistance,drag reduction and hydrophobicity,anti-adhesion,and arrangement,and the non-smooth structure of these different characteristics are applied to the surface of the tool is designed with bionic texture.Furtherly,the cutting performance of bionic textured cutting tools is discussed.The anti-friction and wear-resisting mechanism of bionic textured cutting tools is analyzed.Finally,some pending problems and perspectives have been proposed to provide new inspirations for the design of bionic textured cutting tools.

Research on the Cutting Performance of Cubic Boron Nitride Tools

There were only two kinds of superhard tool material at the past, i.e. diamond and cubic boron nitride (CBN). Manmade diamond and CBN are manufactured by the middle of 20th century. Various manufacturing methods and manmade superhard materials were developed later. They were widely used in different industry and science areas. Recently, a new kind of superhard tool material, C 3N 4 coating film, had been developed. American physical scientists, A. M. Liu and M. L. Cohen, designed a new kind of inorganic compound C 3N 4 with the theory of molecule engineering. According to calculation, it can reach or even exceed the hardness of diamond, so material scientists and technique circles draw their attention to it. A high speed steel twist drill coated with C 3N 4 film is applied to the drilling hole process on steel workpiece in cutting tests, the tool life is increased greatly. When the C 3N 4 film is coated on the cemented carbide inserts, the cutting performance is improved, but is not good enough. The data of mechanical performance and cutting tests about this kind of new tool material is given in this paper, it shows that C 3N 4 has a promising future. The anti-wear ability of cutting tool increases sharply after C 3N 4 being coated on HSS tool. Coated HSS drill also has some benefit after being reground. The tool life prolongs after C 3N 4 being coated on cemented carbide inserts, but is not so long as that of C 3N 4 coated HSS tool. When machining PRCM with C 3N 4 thin-film coated cemented carbide tool, the cutting performance is poor and it is much better when machining PRCM with PCBN, PCD compound plates and CVD thick-film coated cutting tool. Some relative aspects need to be deeply discussed and researched, e.g. the existing coating techniques is not good enough and should be improved in the future, the film thickness should be optimized and try to find out the most effective value, the binding force and mutual effect between coated film and substrate need to be studied furtherly, etc.

MULTI-SCALE AND MULTI-PHASE NANOCOMPOSITE CERAMIC TOOLS AND CUTTING PERFORMANCE

An advanced ceramic cutting tool material Al2O3/TiC/TiN （LTN） is developed by incorporation and dispersion of micro-scale TiC particle and nano-scale TiN particle in alumina matrix. With the optimal dispersing and fabricating technology, this multi-scale and multi-phase nanocomposite ceramic tool material can get both higher flexural strength and fracture toughness than that of A1203/TiC （LZ） ceramic tool material without nano-scale TiN particle, especially the fracture toughness can reach to 7.8 MPa . m^0.5. The nano-scale TiN can lead to the grain fining effect and promote the sintering process to get a higher density. The coexisting transgranular and intergranular fracture mode induced by micro-scale TiC and nano-scale TiN, and the homogeneous and densified microstructure can result in a remarkable strengthening and toughening effect. The cutting performance and wear mechanisms of the advanced multi-scale and multi-phase nanocomposite ceramic cutting tool are researched.

Point-Based Data Analysis for Extracting Parameters of Cutting Tools

Various types of cutting tools are known and are in use for machining parts. The dimensional parameters associated with cutting tools need to be estimated and compared to the desired values for determining their cutting performance. In this paper, a data analysis methodology for extracting parameters from a measured point set corresponding to the surface of a cutting tool is provided. We propose that the 3-D data can be simplified into 2-D data or regular data by virtually slicing it at a predetermined section or by projecting it onto a same axial plane after a simple fixed-axis rotation. A plurality of curves can be generated and optimized based on the obtained 2-D points on a cross section for calculating the section parameters, including radial (axial) rake angle, relief angle, and land width. Other dimensional parameters can also be extracted from the contour of the presented rotary axial projection data. The experimental results have shown that the approaches elaborated in this paper are effective and robust, which can be potentially extended to other applications such as the inspection of similar parts and their parameters extraction.

Comparison of TiAlN, AlCrN, and AlCrN/TiAlN coatings for cutting-tool applications

Monolayer and bilayer coatings of TiAlN, AlCrN, and AlCrN/TiAlN were deposited onto tungsten carbide inserts using the plasma enhanced physical vapor deposition process. The microstructures of the coatings were characterized using scanning electron microscopy （SEM） and atomic force microscopy （AFM）. The SEM micrographs revealed that the AlrN and AlCrN/TiAlN coatings were uniform and highly dense and contained only a limited number of microvoids. The TiAIN coating was non-uniform and highly porous and contained more micro droplets. The hardness and scratch resistance of the specimens were measured using a nanoindentation tester and scratch tester, respectively. Different phases formed in the coatings were analyzed by X-ray diffraction （XRD）. The AlCrN/TiAlN coating exhibited a higher hardness （32.75 GPa）, a higher Young＇s modulus （561.97 GPa）, and superior scratch resistance （LcN = 46 N） compared to conventional coatings such as TiAlN, A1CrN, and TiN.

Reverse Engineering Based Methodology for Redesigning Contour Milling Tools

Reverse Engineering (RE) involves the use of techniques aimed to retrieve information about manufactured products, not only regarding geometries, but also materials and functionality. Today, even if several RE techniques are known, many of them still leave the object unusable to analyze. Nevertheless, other alternatives to this problem allows for obtaining a Digital or Virtual Model (VM) via the three-dimen- sional scanning. Getting the VM of an item, via scanning or not, can offer many possibilities to digital analysis (FEM). Furthermore, starting from VM, it is possible to achieve the physical reproduction of an element, part or workpiece—in the same or different materials—using Additive Manufacturing (AM) technologies. This enables to improve the product through a redesign process. In this paper, a RE based methodology is proposed for redesigning a tool for contour milling, after comparing different microscopy based techniques, 3D-Scanner tools and CAD-CAGD utilities for generating a Virtual Model of the newly designed mill.

Influence of the Magnetic High-speed Steel Cutting Tool on Cutting Capability

The high-speed steel cutting tool has advantaged i n modern cutting tool for its preferable synthetical performance, especially, in a pplication of complicated cutting tools. Therefore, the study of the high-speed steel cutting tools that occupied half of cutting tools has become an importa nt way of studying on modern cutting technology. The cutting performance of hi gh speed-steel cutting tools will be improved by magnetization treating method. Microstructure of high-speed steel will be changed as a result of magnetizatio n, and the effect of mechanism and electromagnetism. Magnetic domain was re-arr anged under outer magnetic field for the magnetism of high-speed steel. When th e high-speed steel tools were treated in pulse magnetic field, the intensity H of which is get to 19 Kves, the boundary of magnetic domain will be replaced ham mered by this kind of intensive pulse, causing flexibility deformation and elast ic stress. The interaction between the elastic field and the initial dislo cation field will lead to expansion and transfer of dislocation, fining of g rains, distortion of crystal lattice, and increase of hardness. Obtained by expe riment, the hardness is raised HRC 0.6～0.9, it is to whole tool. Magnetized in p ulse magnetic field without measure, too many dislocations will accumulate on th e interface of, and the tool will be brittle. Many factors such as magnetic filed intensity, magnetization time and chemical c omponent of high-speed steel will influence the capability of magnetized cuttin g. This paper, according to the test, analyzed and compared the difference effec ts between the magnetized high-speed steel cutting tool and the non-magnet ized high-speed steel cutting tool on cutting force, power, heat, accuracy, ser vice life and etc. It also put forward the relation of cutting factor and cuttin g capability, and the relation of magnetic parameter and cutting capability.

The P40 Cutting Tool Wear Modelization Machining Fk20MnCr5

This work presents an experimental study to describe a wear zone in the P40 cutting tools used during a dry lathing. Mechanics of cutting has been presented to investigate the effects of edge geometry of the cutting tool carbide cutting insert. In the field of the metals cutting, the wear of the cutting tools leads to a degradation of the cutting zone and work. It is thus important to study the evolution of the cutting criteria allowing to follow the tool degradation during a manufacturing operations and thus to decide whether to replace the tool or not. Three parameters: cutting speed, cutting feed and cutting depth are considered to modelize the tool wear. An experimental device, particularly, a work-piece in Fk20MnCr5 material was cutted on a conventional lath for shaping, a high resolution sensor (HRS), had been used for measuring wear zone. The rela- tionship between “the cutting speed, the depth of cut, the feed rate” are analysed and modelled. In order to deduce this shape the spline method to modelize the wear zone has been used and a mathematical model has been proposed.

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.

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.

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

Comparative Study on Tool Fault Diagnosis Methods Using Vibration Signals and Cutting Force Signals by Machine Learning Technique

The state of cutting tool determines the quality of surface produced on the machined parts.A faulty tool produces poor sur face,inaccurate geometry and non-economic production.Thus,it is necessary to monitor tool condition for a.machining process to have superior quality and economic production.In the pre-sent study,fault classification of single point cutting tool for hard turning has been carried out by employing machine learning technique.Cutting force and vibration signals were acquired to monitor tool condition during machining.A set of four tooling conditions namely healthy,worn flank,broken insert and extended tool overhang have been considered for the study.The machine learning technique was applied to both vibration and cutting force signals.Discrete wavelet features of the signals have been extracted using discrete wavelet trans formation(DWT).This transformation represents a large dataset into approximation coeffcients which contain the most useful information of the dataset.Significant features,among features extracted,were selected using J48 decision tree technique.Clas-sification of tool conditions was carried out us ing Naive Bayes algorithm.A 10 fold cross validation was incorporated to test the validity of classifier.A comparison of performance of classifier was made between cutting force and vibration signal to choose the best signal acquisition method in classifying tool fault conditions using machine learning technique.

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.

THE GENERATING THEORY OF THE FLUTES'PROFILE OF SPECIAL REVOLVING TOOLS WITH CONSTANT-SPIRAL-ANGLED EDGES

The manafacturing theory proposed in this paper is composed of the se-lection of the machining type(motions and adjustments)and the determination of thefunctions of motion parameters.The paper shows that the special revolving tools withconstant spiral angled egdes can be ground in the[x y (?)]or[x y z (?)]systembased on the conjugate theory and differential geometry.The functions of motion pa-rameters in these two systems are deduced.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.