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...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.展开更多
High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional ther...High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional thermal resistance and the ability to retain mechanical properties at elevated temperatures of service environment over 700 ℃. However, they are classified as difficult-to-cut materials due to their high shear strength, work hardening tendency, highly abrasive carbide particles in the microstructure, strong tendency to weld and form built-up edge and low thermal conductivity. They have a tendency to maintain their strength at high temperature that is generated during machining. The Inconel 718 workpiece material used in the experiment was in the hot forged and annealed condition. The commercially available inserts (all inserts were made by Kennametal Inc.) were selected for the tests, a PVD TiAlN coated carbide, a CVD/PVD TiN/TiCN/TiN coated carbide and a CVD Al 2O 3/TiC/TiCN coated carbide were used at the cutting speed range about 50～100 m/min. Three kinds Sialon grade inserts with various geometry and cutting angles were used at the cutting speed range from 100 m/min to 300 m/min. For evaluating the inserts machinability when high speed cutting Inconel 718, Taylor Formula within certain cutting speeds, an high speed cutting experiment of tool life was carried out to establish the models of tool life by means of rapid facing turning test. The conclusions drawn from the turning of Inconel 718 with silicon nitride based ceramic; PVD and CVD coated carbide inserts are as follows: Studies on tool wear in high speed machining. The thorough investigations and studies were made on the tool wear form, wear process and wear mechanism in high speed cutting of difficult-to-machine materials with ceramic tools and with coated carbides. The major wear mechanisms of nickel-based alloys are interactions of abrasive wear, adhesion wear, micro-breakout and chipping. Optimization analysis on the application of high speed machining. Based on the experimental results, the optimal cutting parameters were determined for machining of Inconel 718 at high speed. The recommendation of tool inserts for high speed cutting inconel 718 were ceramic inserts of KY2000 with negative rake angle and KY2100 with round type, the PVD coated carbide insert KC7310 was recommended for its lower price.展开更多
In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have...In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have been observed both in the macro scale using a PG-1000 light microscope and in the micro scale using a Scanning Electron Microscope (SEM) respectively. These observations indicate that most of these tool fractures are the result of tool chipping. Further analysis of each chipping event has shown that beachmarks emanate from points on the cutting edge. This visual evidence indicates that the cutting edge is failing in fatigue due to cyclical mechanical and/or thermal stresses. Initial analyses explaining some of the outlying conditions for this phenomenon are discussed. Future analysis regarding determining the underlying causes of the fatigue phenomenon is then outlined.展开更多
Graphite becomes the prevailing electrode material in electrical discharging machining （EDM）currently.Orthogonal cutting experiments are carried out to study the characteristics of graphite chip formation process.Hi...Graphite becomes the prevailing electrode material in electrical discharging machining （EDM）currently.Orthogonal cutting experiments are carried out to study the characteristics of graphite chip formation process.High speed milling experiments are conducted to study tool wear and cutting forces.The results show that depth of cut has great influence on graphite chip formation.The removal process of graphite in high speed milling is the mutual result of cutting and grinding process. Graphite is prone to cause severe abrasion wear to coated carbide endmills due to its high abrasiveness nature.The major patterns of tool wear are flank wear,rake wear,micro-chipping and breakage. Cutting forces can be reduced by adoption of higher cutting speed,moderate feed per tooth,smaller radial and axial depths of cut,and up cutting.展开更多
In this paper, a series of experiments were performed by high speed milling of Ti-6.5Al-2Zr-1Mo-1V (TA15) by use of polycrystalline diamond (PCD) tools. The characteristics of high speed machining (HSM) dynamic millin...In this paper, a series of experiments were performed by high speed milling of Ti-6.5Al-2Zr-1Mo-1V (TA15) by use of polycrystalline diamond (PCD) tools. The characteristics of high speed machining (HSM) dynamic milling forces were investi- gated. The effects of the parameters of the process, i.e., cutting speed, feed per tooth, and depth of axial cut, on cutting forces were studied. The cutting force signals under different cutting speed conditions and different cutting tool wear stages were analyzed by frequency spectrum analysis. The trend and frequency domain aspects of the dynamic forces were evaluated and discussed. The results indicate that a characteristic frequency in cutting force power spectrum does in fact exist. The amplitudes increase with the increase of cutting speed and tool wear level, which could be applied to the monitoring of the cutting process.展开更多
This paper begins with a consideration of the influence of feed per revolution upon the depth of a cut and the impact of the machining method on the direction of tool pressure average and subsequent description of eff...This paper begins with a consideration of the influence of feed per revolution upon the depth of a cut and the impact of the machining method on the direction of tool pressure average and subsequent description of efficient cutting directions and the methods for load cell orientation. The paper goes further into the key conclusions concerning the dependences of the cutting depth at high-speed milling as in the case of discontinuous functions. It ends with recommendations offered for positioning of load cells for cut-up milling and cut-down milling.展开更多
The present work aims at the microstructural characterization of TiAlZrN/ Al2O3 and TiAlZrN/Si3N4 coatings deposited via lateral rotating cathodes. The coatings were deposited using Lateral Rotating Cathodes (LARC) te...The present work aims at the microstructural characterization of TiAlZrN/ Al2O3 and TiAlZrN/Si3N4 coatings deposited via lateral rotating cathodes. The coatings were deposited using Lateral Rotating Cathodes (LARC) technology. The deposited coatings were studied for its cross sectional morphology using scanning electron microscopy. Energy Dispersive Spectrometry was also conducted along the cross section to determine the elemental composition. Micro Vickers hardness test was conducted to determine the hardness of the coatings. The scanning electron microscope images showed that TiAlZrN/Al2O3 coatings showed preferred columnar grain orientation with multilayered structure while TiAlZrN/Si3N4 coatings exhibit a dense grain structure. The TiAlZrN/Si3N4 coating shows a hardness of 31.58 GPa while TiAlZrN/Al2O3 coating shows a hardness of 25.40 GPa. Dry turning tests were performed on AISI 304 stainless steel. The TiAlZrN/Si3N4 coatings show reduced flank wear. Both the coatings even under severe cutting conditions impart surface roughness of less than 1.5 μm.展开更多
Titanium alloys are widely used in aeronautics that demand a good combination of high strength, good corrosion resistance and low mass. The mechanical properties lead to challenges in machining operations such as high...Titanium alloys are widely used in aeronautics that demand a good combination of high strength, good corrosion resistance and low mass. The mechanical properties lead to challenges in machining operations such as high process temperature as well as rapidly increasing tool wear. The conventional tool materials are not able to maintain their hardness and other mechanical prop- erties at higher cutting temperatures encountered in high speed machining. In this work, the new material tools, which are poly- crystalline diamond （PCD） and polycrystalline cubic boron nitride （PCBN） tools, are used in high-speed milling of Ti-6.5AI-2Zr-IMo-IV （TA15） alloy. The performance and wear mechanism of the tools are investigated. Compared to PCBN tool, PCD tool has a much longer tool life, especially at higher cutting speeds. Analyses based on the SEM and EDX suggest that attrition, adhesion and diffusion are the main wear mechanisms of PCD and PCBN tools in high-speed milling of TA 15. Oxida- tion wear is also observed at PCBN tool/workpiece interface. Roughness, defects, micro-hardness and microstructure of the ma- chined surface are investigated. The recorded surface roughness values with PCD/PCBN tools are bellow 0.3 μm at initial and steady cutting stage. Micro-hardness analysis shows that the machined surface hardening depth with PCD and PCBN tools is small. There is no evidence of sub-surface defects with PCD and PCBN tools. It is concluded that for TA15 alloy, high-speed milling can be carried out with PCD/PCBN tools.展开更多
Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix...Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix composite （TMCs）. The combined effects of abrasive wear and diffusion wear caused the big crater on PCD and carbide tool rake face. Compared to the PCD, bigger size of crater was found on the carbide tool due to much higher cutting temperature and the violent chemical reaction between the Ti element in the workpiece and the WC in the tool. However, the marks of the abrasive wear looked much slighter or even could not be observed on the carbide tool especially when low levels of cutting parameters were used, which attributes to much lower hardness and smaller size of WC combined with more significant chemical degradation of carbide. When cutting TC4 using PCD tool, notch wear was the most significant wear pattern which was not found when cutting the TMCs. However, chipping, adhesive wear and crater wear were much milder when compared to the cutting of titanium matrix composite. Due to the absence of abrasive wear when cutting TC4, the generated titanium carbide on the PCD protected the tool from fast wear, which caused that the tool life for TC4 was 6-10 times longer than that for TMCs.展开更多
文摘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.
文摘High speed machining (HSM) technology is one of important aspects of advanced manufacturing technology. Nickel-based superalloys have been widely used in the aircraft and nuclear industry due to their exceptional thermal resistance and the ability to retain mechanical properties at elevated temperatures of service environment over 700 ℃. However, they are classified as difficult-to-cut materials due to their high shear strength, work hardening tendency, highly abrasive carbide particles in the microstructure, strong tendency to weld and form built-up edge and low thermal conductivity. They have a tendency to maintain their strength at high temperature that is generated during machining. The Inconel 718 workpiece material used in the experiment was in the hot forged and annealed condition. The commercially available inserts (all inserts were made by Kennametal Inc.) were selected for the tests, a PVD TiAlN coated carbide, a CVD/PVD TiN/TiCN/TiN coated carbide and a CVD Al 2O 3/TiC/TiCN coated carbide were used at the cutting speed range about 50～100 m/min. Three kinds Sialon grade inserts with various geometry and cutting angles were used at the cutting speed range from 100 m/min to 300 m/min. For evaluating the inserts machinability when high speed cutting Inconel 718, Taylor Formula within certain cutting speeds, an high speed cutting experiment of tool life was carried out to establish the models of tool life by means of rapid facing turning test. The conclusions drawn from the turning of Inconel 718 with silicon nitride based ceramic; PVD and CVD coated carbide inserts are as follows: Studies on tool wear in high speed machining. The thorough investigations and studies were made on the tool wear form, wear process and wear mechanism in high speed cutting of difficult-to-machine materials with ceramic tools and with coated carbides. The major wear mechanisms of nickel-based alloys are interactions of abrasive wear, adhesion wear, micro-breakout and chipping. Optimization analysis on the application of high speed machining. Based on the experimental results, the optimal cutting parameters were determined for machining of Inconel 718 at high speed. The recommendation of tool inserts for high speed cutting inconel 718 were ceramic inserts of KY2000 with negative rake angle and KY2100 with round type, the PVD coated carbide insert KC7310 was recommended for its lower price.
文摘In high speed milling of titanium alloys the high rate of tool failure is the main reason for its high manufacturing cost. In this study,fractured tools which were used in a titanium alloys 5-axis milling process have been observed both in the macro scale using a PG-1000 light microscope and in the micro scale using a Scanning Electron Microscope (SEM) respectively. These observations indicate that most of these tool fractures are the result of tool chipping. Further analysis of each chipping event has shown that beachmarks emanate from points on the cutting edge. This visual evidence indicates that the cutting edge is failing in fatigue due to cyclical mechanical and/or thermal stresses. Initial analyses explaining some of the outlying conditions for this phenomenon are discussed. Future analysis regarding determining the underlying causes of the fatigue phenomenon is then outlined.
基金Selected from Proceedings of the 7th International Conference on Frontiers of Design and Manufacturing(ICFDM'2006)This project is supported by National Natural Science Foundation of China(No.50605008).
文摘Graphite becomes the prevailing electrode material in electrical discharging machining （EDM）currently.Orthogonal cutting experiments are carried out to study the characteristics of graphite chip formation process.High speed milling experiments are conducted to study tool wear and cutting forces.The results show that depth of cut has great influence on graphite chip formation.The removal process of graphite in high speed milling is the mutual result of cutting and grinding process. Graphite is prone to cause severe abrasion wear to coated carbide endmills due to its high abrasiveness nature.The major patterns of tool wear are flank wear,rake wear,micro-chipping and breakage. Cutting forces can be reduced by adoption of higher cutting speed,moderate feed per tooth,smaller radial and axial depths of cut,and up cutting.
基金Project (No.IRT0837) supported by the Program for Changjiang Scholars and Innovative Research Team in University of China
文摘In this paper, a series of experiments were performed by high speed milling of Ti-6.5Al-2Zr-1Mo-1V (TA15) by use of polycrystalline diamond (PCD) tools. The characteristics of high speed machining (HSM) dynamic milling forces were investi- gated. The effects of the parameters of the process, i.e., cutting speed, feed per tooth, and depth of axial cut, on cutting forces were studied. The cutting force signals under different cutting speed conditions and different cutting tool wear stages were analyzed by frequency spectrum analysis. The trend and frequency domain aspects of the dynamic forces were evaluated and discussed. The results indicate that a characteristic frequency in cutting force power spectrum does in fact exist. The amplitudes increase with the increase of cutting speed and tool wear level, which could be applied to the monitoring of the cutting process.
文摘This paper begins with a consideration of the influence of feed per revolution upon the depth of a cut and the impact of the machining method on the direction of tool pressure average and subsequent description of efficient cutting directions and the methods for load cell orientation. The paper goes further into the key conclusions concerning the dependences of the cutting depth at high-speed milling as in the case of discontinuous functions. It ends with recommendations offered for positioning of load cells for cut-up milling and cut-down milling.
文摘The present work aims at the microstructural characterization of TiAlZrN/ Al2O3 and TiAlZrN/Si3N4 coatings deposited via lateral rotating cathodes. The coatings were deposited using Lateral Rotating Cathodes (LARC) technology. The deposited coatings were studied for its cross sectional morphology using scanning electron microscopy. Energy Dispersive Spectrometry was also conducted along the cross section to determine the elemental composition. Micro Vickers hardness test was conducted to determine the hardness of the coatings. The scanning electron microscope images showed that TiAlZrN/Al2O3 coatings showed preferred columnar grain orientation with multilayered structure while TiAlZrN/Si3N4 coatings exhibit a dense grain structure. The TiAlZrN/Si3N4 coating shows a hardness of 31.58 GPa while TiAlZrN/Al2O3 coating shows a hardness of 25.40 GPa. Dry turning tests were performed on AISI 304 stainless steel. The TiAlZrN/Si3N4 coatings show reduced flank wear. Both the coatings even under severe cutting conditions impart surface roughness of less than 1.5 μm.
基金National High-tech Research and Development Program of China (2009AA04Z116)Program for Changjiang Scholars and Innovative Research Team in University ( IRT0837)
文摘Titanium alloys are widely used in aeronautics that demand a good combination of high strength, good corrosion resistance and low mass. The mechanical properties lead to challenges in machining operations such as high process temperature as well as rapidly increasing tool wear. The conventional tool materials are not able to maintain their hardness and other mechanical prop- erties at higher cutting temperatures encountered in high speed machining. In this work, the new material tools, which are poly- crystalline diamond （PCD） and polycrystalline cubic boron nitride （PCBN） tools, are used in high-speed milling of Ti-6.5AI-2Zr-IMo-IV （TA15） alloy. The performance and wear mechanism of the tools are investigated. Compared to PCBN tool, PCD tool has a much longer tool life, especially at higher cutting speeds. Analyses based on the SEM and EDX suggest that attrition, adhesion and diffusion are the main wear mechanisms of PCD and PCBN tools in high-speed milling of TA 15. Oxida- tion wear is also observed at PCBN tool/workpiece interface. Roughness, defects, micro-hardness and microstructure of the ma- chined surface are investigated. The recorded surface roughness values with PCD/PCBN tools are bellow 0.3 μm at initial and steady cutting stage. Micro-hardness analysis shows that the machined surface hardening depth with PCD and PCBN tools is small. There is no evidence of sub-surface defects with PCD and PCBN tools. It is concluded that for TA15 alloy, high-speed milling can be carried out with PCD/PCBN tools.
基金supported by the National Natural Science Foundation of China (No.51275227)Nanjing Science and Technology Development Plan (201306024) of Chinathe Qinglan Project of Jiangsu Province (2014) of China
文摘Chipping, adhesive wear, abrasive wear and crater wear are prevalent for both the polycrystalline diamond （PCD） and the carbide tools during high speed turning of TiCp/TiBw hybrid reinforced Ti-6Al-4V （TC4） matrix composite （TMCs）. The combined effects of abrasive wear and diffusion wear caused the big crater on PCD and carbide tool rake face. Compared to the PCD, bigger size of crater was found on the carbide tool due to much higher cutting temperature and the violent chemical reaction between the Ti element in the workpiece and the WC in the tool. However, the marks of the abrasive wear looked much slighter or even could not be observed on the carbide tool especially when low levels of cutting parameters were used, which attributes to much lower hardness and smaller size of WC combined with more significant chemical degradation of carbide. When cutting TC4 using PCD tool, notch wear was the most significant wear pattern which was not found when cutting the TMCs. However, chipping, adhesive wear and crater wear were much milder when compared to the cutting of titanium matrix composite. Due to the absence of abrasive wear when cutting TC4, the generated titanium carbide on the PCD protected the tool from fast wear, which caused that the tool life for TC4 was 6-10 times longer than that for TMCs.
